Preparation method of photocatalyst sterilizing, flame-retardant and sound-insulating automotive carpet

Abstract

The invention provides a preparation method of a photocatalyst sterilizing, flame-retardant and sound-insulating automotive carpet. The automotive carpet comprises a surface decoration layer, an isolation layer, a framework layer and a porous sponge rubber layer, flame retardant powder is added into the isolation layer, and photocatalyst powder is added into the sponge rubber layer; the surface decoration layer, the isolation layer, the framework layer and the sponge rubber layer are stacked together from top to bottom, then placed into a setting machine to be heated and then subjected to compression molding, and the automobile carpet is obtained after compression molding is completed. The isolation layer has good flame-retardant performance and can protect the skeleton layer and the sponge rubber layer from the upper part in a flame-retardant manner, so that the flame-retardant performance and effect are improved; the sponge rubber layer at the bottommost layer is made of a porous structure material and has excellent performances of shock absorption, sound insulation, heat insulation, water absorption, dust absorption and the like; and photocatalyst powder is added into the sponge rubber layer, so that the automobile carpet has the functions of deodorization, sterilization, mildew prevention, pollution prevention, self-cleaning and the like under the light condition.

Description

Technical Field

[0001] The invention belongs to the technical field of automobile interior decoration, and in particular relates to a method for preparing a photocatalyst sterilizing, flame-retardant and sound-insulating automobile carpet. Background Art

[0002] Car carpets are widely used in the decoration of motor vehicle cabs and are an important automotive interior decoration part because of their sound insulation, shock absorption, warmth retention, soft stepping feeling, high riding comfort, water absorption, dust absorption and other functions. At present, car carpets include: cotton felt type and polyurethane PU foam type.

[0003] Photocatalyst, also known as photocatalyst, is a general term for semiconductor materials with photocatalytic functions, represented by nano-scale titanium dioxide; the representative photocatalyst material is nano-titanium dioxide, which can produce strong oxidizing substances (such as hydroxyl free radicals, oxygen, etc.) under light irradiation, and can be used to decompose organic compounds, some inorganic compounds, bacteria and viruses, etc.; in daily life, photocatalysts can effectively degrade toxic and harmful gases in the air such as formaldehyde, efficiently purify the air, and effectively kill a variety of bacteria, and can decompose and harmlessly treat toxins released by bacteria or fungi; it can significantly and continuously eliminate harmful gases such as formaldehyde, benzene, TVOC, etc., and at the same time have the effects of deodorization, sterilization, mildew prevention, anti-fouling and self-cleaning, and air purification.

[0004] Therefore, with the advancement of science and technology and economic development, how to optimize the functions of car carpets so that they can increase flame retardancy and produce deodorization, sterilization, mildew prevention, anti-fouling and self-cleaning functions under light conditions is a technical problem that technical personnel in this field urgently need to solve. Summary of the invention

[0005] The purpose of the present invention is to provide a method for preparing a photocatalyst sterilizing, flame-retardant and sound-insulating automobile carpet.

[0006] In order to achieve the above object, the technical solution of the present invention is as follows:

[0007] A method for preparing a photocatalyst sterilization, flame retardancy and sound insulation automobile carpet, the automobile carpet comprising a surface decoration layer, an insulation layer, a skeleton layer and an open-pore sponge rubber layer;

[0008] Flame retardant powder is added to the insulating layer, and photocatalyst powder is added to the sponge rubber layer;

[0009] The surface decoration layer, the insulating layer, the skeleton layer and the sponge rubber layer are stacked together in order from top to bottom, and then placed in a molding machine for heating, and then molded to obtain a car carpet.

[0010] Preferably, the method specifically comprises the following steps performed in sequence:

[0011] 1) The PET fibers are sequentially opened, mixed, combed, laid, needled, rolled, raised, and rolled to form a surface decorative layer;

[0012] 2) Mix PE, PA and flame retardant powder evenly, pour into the mold after melting, and form an insulation layer after solidification;

[0013] 3) PET, PP and pure cotton are sequentially opened, mixed, combed, laid, needled and blanched to obtain a skeleton layer;

[0014] 4) preparing raw materials, including raw rubber, foaming agent, vulcanizing agent and photocatalyst powder, and then performing plastication and mixing in sequence, and then performing thin-pass plastication, and then performing vulcanization and foaming, and after completion, a sponge rubber layer is obtained;

[0015] 5) The surface decoration layer, the insulating layer, the skeleton layer, and the sponge rubber layer are stacked together in order from top to bottom, and then placed in a molding machine for heating, and then molded to obtain a car carpet.

[0016] Preferably, the method for preparing the sponge rubber layer specifically comprises the following steps performed in sequence:

[0017] 4.1) Prepare raw materials: Raw materials include raw rubber, foaming agent, vulcanizing agent, photocatalyst powder, activator, vulcanization accelerator and coagulant;

[0018] Plasticize the raw rubber;

[0019] 4.2) Mixing: Add the raw materials in step 4.1) into an internal mixer for mixing, and obtain a mixed material after mixing;

[0020] 4.3) Thin-pass plastication: The mixed material obtained in step 4.2) is subjected to thin-pass plastication to obtain thin-pass sheets;

[0021] 4.4) Vulcanization and foaming: vulcanizing the thin sheet obtained in step 4.3), foaming and forming simultaneously during the vulcanization process, and obtaining a sponge rubber layer after cooling, wherein the photocatalyst particles are pre-embedded in the pore walls of the openings in the sponge rubber layer;

[0022] 4.5) Solvent etching: A solvent is applied to the sponge rubber layer, and the surface layer of the hole wall of the sponge rubber layer is dissolved and corroded by the solvent, so that a part of the volume of the photocatalyst particles pre-embedded in the hole wall is exposed to the outside, so that a part of the volume of the photocatalyst particles is exposed to the atmosphere and directly contacts with external bacteria, viruses, dirt, and odor, so that the strong oxidizing substances generated by the photocatalyst particles are directly contacted with external bacteria, viruses, dirt, and odor, and the remaining part of the volume of the photocatalyst particles is still pre-embedded in the hole wall, so that the hole wall fixes the remaining part of the volume of the photocatalyst particles to prevent the photocatalyst particles from falling from the car carpet;

[0023] After etching for a period of time, the sponge rubber layer is rinsed with ethanol to remove the residual solvent after the reaction, and then washed with water until the water is neutral, and then dried to obtain the etched sponge rubber layer.

[0024] Preferably, in step 4.1), the raw materials include the following components in parts by weight: 95-98 parts of raw rubber, 0.6-1.2 parts of foaming agent, 0.7-1.2 parts of vulcanizing agent, 2-5 parts of photocatalyst powder, 0.7-1.4 parts of activator, 0.7-1.4 parts of vulcanization accelerator, and 0.7-1.4 parts of coagulant;

[0025] The raw rubber is nitrile rubber or styrene butadiene rubber;

[0026] The foaming agent is potassium oleate;

[0027] The vulcanizing agent is sulfur;

[0028] The photocatalyst powder is nano titanium dioxide powder; the particle size of the photocatalyst powder is 70-100 nanometers;

[0029] The activator is a zinc oxide dispersion;

[0030] The vulcanization accelerator is diphenylguanidine;

[0031] The coagulant is sodium alginate.

[0032] Preferably, in step 4.2), the mixing temperature is 90°C-100°C, and the mixture is kneaded until the plasticity is 0.5-0.6.

[0033] Preferably, in step 4.3), the number of thin-pass mastication is 4-6 times, followed by a rest period of 1-3 days, and then thin-pass mastication again for 1.5-3.5 minutes.

[0034] Preferably, in step 4.4), the vulcanization is performed in a mold for vulcanization and foaming, the vulcanization temperature is 150° C.-170° C., the vulcanization time is 10 min-20 min, and the vulcanization pressure is 2.5-3.5 MPa;

[0035] The foaming degree is controlled so that the thickness of the hole wall is 0.1-0.3 micrometers, and the maximum inner diameter of the opening is less than or equal to the particle diameter of the photocatalyst particles, so that the photocatalyst particles cannot fall out of the etched sponge rubber layer.

[0036] Preferably, in step 4.5), when the raw rubber is nitrile rubber, the solvent used to dissolve and corrode the nitrile rubber is acetone, methyl ethyl ketone, chloroform, ethylene dichloride, trichloroethylene or ethyl acetate;

[0037] The coating method is to spray the solvent onto the sponge rubber layer or immerse the sponge rubber layer in the solvent;

[0038] The solvent is dissolved in ethanol, the mass percentage concentration of the solvent is controlled to be 10%-25%, and the solvent corrosion time is controlled to be 5-20 minutes, so that the surface thickness of the hole wall is dissolved and corroded to account for 20%-40% of the total thickness of the hole wall.

[0039] This application has achieved the following beneficial technical effects:

[0040] In the present application, flame retardant powder is added to the insulating layer, so that the insulating layer has good flame retardant properties. The insulating layer belongs to the middle and upper layers among the layers in the car carpet, so that when cigarette butts, cigarette ashes, lighters, fireworks, organic aerosols and other flammable materials dropped by passengers during smoking fall on the car carpet, the insulating layer can flame retardantly protect the skeleton layer and sponge rubber layer below from the upper part, thereby improving the overall flame retardant properties and flame retardant effect of the car carpet;

[0041] In the present application, the bottom layer of the car carpet is an open-pore sponge rubber layer, which is a porous structure material with holes throughout the material. It has a low density, excellent elasticity and flexibility, and has excellent shock absorption, sound insulation, heat insulation, water absorption, dust absorption and other properties; the sponge rubber layer is a vulcanized rubber with a sponge-like porous structure, which is light, soft, elastic, not easy to conduct heat, and has the functions of shockproof, impact mitigation, heat insulation, sound insulation, etc.

[0042] The present application adds photocatalyst powder to the raw materials of the sponge rubber layer. After plasticating, mixing, thinning, vulcanization and foaming, the obtained car carpet contains photocatalyst, so that the car carpet has the functions of deodorization, sterilization, mildew prevention, anti-fouling and self-cleaning under light conditions. DETAILED DESCRIPTION

[0043] The following will be combined with the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. The described embodiments are only some embodiments of the present invention, not all. Therefore, based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0044] The present application provides a method for preparing a photocatalytic sterilization, flame retardant and sound-insulating automotive carpet, wherein the automotive carpet comprises a surface decoration layer, an insulation layer, a skeleton layer and an open-pore sponge rubber layer;

[0045] Flame retardant powder is added to the insulating layer, and photocatalyst powder is added to the sponge rubber layer;

[0046] The surface decoration layer, the insulating layer, the skeleton layer and the sponge rubber layer are stacked together in order from top to bottom, and then placed in a molding machine for heating, and then molded to obtain a car carpet.

[0047] In one embodiment of the present application, the following steps are specifically included:

[0048] 1) The PET fibers are sequentially opened, mixed, combed, laid, needled, rolled, raised, and rolled to form a surface decorative layer;

[0049] 2) Mix PE, PA and flame retardant powder evenly, pour into the mold after melting, and form an insulation layer after solidification;

[0050] 3) PET, PP and pure cotton are sequentially opened, mixed, combed, laid, needled and blanched to obtain a skeleton layer;

[0051] 4) preparing raw materials, including raw rubber, foaming agent, vulcanizing agent and photocatalyst powder, and then performing plastication and mixing in sequence, and then performing thin-pass plastication, and then performing vulcanization and foaming, and after completion, a sponge rubber layer is obtained;

[0052] 5) The surface decoration layer, the insulating layer, the skeleton layer, and the sponge rubber layer are stacked together in order from top to bottom, and then placed in a molding machine for heating, and then molded to obtain a car carpet.

[0053] In one embodiment of the present application, the method for preparing the sponge rubber layer specifically comprises the following steps performed in sequence:

[0054] 4.1) Prepare raw materials: Raw materials include raw rubber, foaming agent, vulcanizing agent, photocatalyst powder, activator, vulcanization accelerator and coagulant;

[0055] Plasticize the raw rubber;

[0056] 4.2) Mixing: Add the raw materials in step 4.1) into an internal mixer for mixing, and obtain a mixed material after mixing;

[0057] 4.3) Thin-pass plastication: The mixed material obtained in step 4.2) is subjected to thin-pass plastication to obtain thin-pass sheets;

[0058] 4.4) Vulcanization and foaming: vulcanizing the thin sheet obtained in step 4.3), foaming and forming simultaneously during the vulcanization process, and obtaining a sponge rubber layer after cooling, wherein the photocatalyst particles are pre-embedded in the pore walls of the openings in the sponge rubber layer;

[0059] 4.5) Solvent etching: A solvent is applied to the sponge rubber layer, and the surface layer of the hole wall of the sponge rubber layer is dissolved and corroded by the solvent, so that a part of the volume of the photocatalyst particles pre-embedded in the hole wall is exposed to the outside, so that a part of the volume of the photocatalyst particles is exposed to the atmosphere and directly contacts with external bacteria, viruses, dirt, and odor, so that the strong oxidizing substances generated by the photocatalyst particles are directly contacted with external bacteria, viruses, dirt, and odor, and the remaining part of the volume of the photocatalyst particles is still pre-embedded in the hole wall, so that the hole wall fixes the remaining part of the volume of the photocatalyst particles to prevent the photocatalyst particles from falling from the car carpet;

[0060] After etching for a period of time, the sponge rubber layer is rinsed with ethanol to remove the residual solvent after the reaction, and then washed with water until the water is neutral, and then dried to obtain the etched sponge rubber layer.

[0061] In one embodiment of the present application, in step 4.1), the raw materials include the following components in parts by mass: 95-98 parts of raw rubber, 0.6-1.2 parts of foaming agent, 0.7-1.2 parts of vulcanizing agent, 2-5 parts of photocatalyst powder, 0.7-1.4 parts of activator, 0.7-1.4 parts of vulcanization accelerator, and 0.7-1.4 parts of coagulant;

[0062] The raw rubber is nitrile rubber or styrene butadiene rubber;

[0063] The foaming agent is potassium oleate;

[0064] The vulcanizing agent is sulfur;

[0065] The photocatalyst powder is nano titanium dioxide powder; the particle size of the photocatalyst powder is 70-100 nanometers;

[0066] The activator is a zinc oxide dispersion;

[0067] The vulcanization accelerator is diphenylguanidine;

[0068] The coagulant is sodium alginate.

[0069] In one embodiment of the present application, in step 4.2), the mixing temperature is 90°C-100°C, and the mixing is performed until the plasticity is 0.5-0.6.

[0070] In one embodiment of the present application, in step 4.3), the number of thin-pass mastication is 4-6 times, followed by a rest period of 1-3 days, and then thin-pass mastication is performed again for 1.5-3.5 minutes.

[0071] In one embodiment of the present application, in step 4.4), the vulcanization is performed in a mold for vulcanization and foaming, the vulcanization temperature is 150° C.-170° C., the vulcanization time is 10 min-20 min, and the vulcanization pressure is 2.5-3.5 MPa;

[0072] The foaming degree is controlled so that the thickness of the hole wall is 0.1-0.3 micrometers, and the maximum inner diameter of the opening is less than or equal to the particle diameter of the photocatalyst particles, so that the photocatalyst particles cannot fall out of the etched sponge rubber layer.

[0073] In one embodiment of the present application, in step 4.5), when the raw rubber is nitrile rubber, the solvent used to dissolve and corrode the nitrile rubber is acetone, methyl ethyl ketone, chloroform, ethylene dichloride, trichloroethylene or ethyl acetate;

[0074] The coating method is to spray the solvent onto the sponge rubber layer or immerse the sponge rubber layer in the solvent;

[0075] The solvent is dissolved in ethanol, the mass percentage concentration of the solvent is controlled to be 10%-25%, and the solvent corrosion time is controlled to be 5-20 minutes, so that the surface thickness of the hole wall is dissolved and corroded to account for 20%-40% of the total thickness of the hole wall.

[0076] In the present application, the mass ratio of PA nylon to PE polyethylene in the insulating layer is 1:(2.5-3.5);

[0077] The mass ratio of PP polypropylene, polyethylene terephthalate PET and pure cotton in the skeleton layer is 2:(4.5-5.5):(2.5-3.5).

[0078] In the present application, the flame retardant is aluminum hydroxide powder and / or magnesium hydroxide powder.

[0079] In the above-mentioned sponge rubber layer, nano-scale photocatalyst particles are embedded in the pore walls of the openings in the sponge rubber layer. The nano-scale photocatalyst particles are completely wrapped by the thicker pore walls, which will result in the photocatalyst particles being unable to come into direct contact with external bacteria, viruses, dirt, odors, etc., and the strong oxidizing substances (such as hydroxyl radicals, oxygen, etc.) generated by the photocatalyst particles are also unable to penetrate the pore walls and come into direct contact with external bacteria, viruses, dirt, odors, etc., thus significantly limiting and weakening the effects and efficiencies of the photocatalyst in deodorization, sterilization, mildew prevention, antifouling and self-cleaning;

[0080] To this end, the present application applies a solvent to the sponge rubber layer, and uses the solvent to dissolve and corrode the surface layer of the hole wall of the opening in the sponge rubber layer, and the solvent does not react with the photocatalyst particles, so that a part of the volume (a part of the volume of a single photocatalyst particle) of the photocatalyst particles (a part of the number, more or less, not all the number) pre-embedded in the hole wall is exposed to the outside, that is, a part of the volume of the photocatalyst particles is exposed to the atmosphere, so that the photocatalyst particles are conveniently in direct contact with external bacteria, viruses, dirt, odor, etc., and the strong oxidizing substances generated by the photocatalyst are conveniently in direct contact with external bacteria, viruses, dirt, odor, etc., thereby ensuring and improving the deodorization, sterilization, mildew prevention, antifouling and self-cleaning effects and efficiency of the car carpet of the photocatalyst;

[0081] Furthermore, it does not mean that it would be better to completely separate the volume of the photocatalyst particles from the pore walls so that the entire volume is exposed to the atmosphere and the contact area with the outside world is larger. Because the volume of the photocatalyst particles is completely separated from the pore walls, the photocatalyst particles become completely free, not tied, connected or fixed by other objects such as the pore walls, and drift freely like rootless duckweed, drifting wherever they go. As a result, the photocatalyst particles are easily vibrated, rubbed, and dropped out of the car carpet during use, resulting in a decrease in the number of photocatalyst particles in the car carpet as the use time increases, and the purification and sterilization capabilities become weaker and weaker.

[0082] To this end, the solvent is used to corrode and remove only the surface layer of the hole wall of the opening, so that the remaining volume of the photocatalyst particles is still embedded in the hole wall, that is, the hole wall still has a fixed support effect on the photocatalyst particles, and the photocatalyst particles are firmly fixed in the hole wall in the car carpet, and will not fall off and slide out of the car carpet. The number of photocatalyst particles will not decrease, and the purification and sterilization capabilities of the photocatalyst will not decrease, so that the photocatalyst is effective for a long time, and the use time and use effect of the deodorization, sterilization, mildew prevention, antifouling and self-cleaning functions of the photocatalyst car carpet are significantly improved;

[0083] That is, the volume of the photocatalyst particles must be exposed but not completely. The volume of the photocatalyst particles can only be partially exposed and partially not exposed. Therefore, this is a technical contradiction. Therefore, it is more appropriate and more effective to use an etching process here. The etching process only corrodes away the surface layer in a short time and leaves the rest of the lower layer. This solves the above-mentioned technical contradiction more perfectly. Just like chip etching, useless parts are corroded away at the nanometer level, leaving useful parts, and finally a circuit diagram is formed at the nanometer level.

[0084] In this application, raw rubber (raw rubber) is a polymer material with unique high elasticity, which is the parent material for manufacturing rubber products, and generally refers to unvulcanized rubber. Vulcanized rubber refers to vulcanized rubber, which has the characteristics of not becoming sticky and not easy to break, and is also called cooked rubber. After vulcanization, a three-dimensional structure is formed in the raw rubber, which has high elasticity, heat resistance, tensile strength and insolubility in organic solvents. Most rubber products are vulcanized rubber.

[0085] In the present application, the closed plastic mixer is referred to as the internal mixer. There is a pair of rotors rotating in opposite directions in the internal mixer. The rotors are pear-shaped in cross section and Z-shaped spirals along the longitudinal direction. The outer wall has a cooling (heating) jacket to heat and cool the material. The internal mixer is a mixing machine in a closed cylindrical container that gives shearing action to the material by means of the rotation of a paddle impeller. The material temperature can be adjusted by heating or cooling, and it is used for mixing plastics or rubber.

[0086] In the present application, the thin-pass plastication method is to ensure that the roller gap of the open mixing mill is below 1 mm, and the rubber material does not wrap around the rollers after passing through the roller gap but falls directly on the receiving plate. After the rubber material has all passed through the roller gap, the rubber material is returned to the top of the roller gap and passes through the roller gap again. This is repeated several times until the required plasticity is reached; the higher the plasticity requirement of the rubber material, the more times it needs to pass through the roller gap; it is mainly to improve the mixing effect of the mixed rubber and make the various components in the mixed rubber, such as carbon black, vulcanizer, antioxidant, etc., evenly dispersed.

[0087] In the present application, etching is a technique that uses chemical reactions or physical impacts to remove part of a material. Etching techniques can be divided into two categories: wet etching and dry etching. It can be used to manufacture printing embossed plates such as copper plates and zinc plates at the earliest, and is also widely used to reduce the weight of instrument panels, nameplates, and thin workpieces that are difficult to process using traditional processing methods. After continuous improvements and development of process equipment, it can also be used for the processing of precision etching products of electronic thin-film parts in the aviation, machinery, and chemical industries. In particular, etching is an indispensable technique in semiconductor manufacturing processes, as well as etching of printed circuit boards (PCBs). PCB etching is the process of spraying an etching solution evenly onto the surface of a copper foil through a nozzle under certain temperature conditions, causing an oxidation-reduction reaction with copper that is not protected by an etching resist, thereby reacting away the unnecessary copper, exposing the substrate, and then stripping the film to form the circuit.

[0088] In the present application, nitrile rubber is easily soluble in chlorinated hydrocarbons, nitro hydrocarbons, aromatic hydrocarbons, ketones, acids, carboxylic acids and hydroxy compounds, so the solvents used are relatively wide and can be reasonably selected according to the requirements of use such as volatilization speed, the properties of the compounding agent, the toxicity of the solvent and the cost. If a fast volatilization speed is required, solvents such as acetone, methyl ethyl ketone, chloroform, dichloroethylene, trichloroethylene, ethyl acetate, etc. can be used; if a slow volatilization speed is required, nitromethane, nitroethane, nitropropane, chlorobenzene, chlorotoluene, dioxane, butyl acetate, etc. can be used. Nitrile rubber with a high acrylonitrile content can only be dissolved in ketones, nitro hydrocarbons and chlorinated hydrocarbon solvents, and nitrile rubber adhesives with a high solid content generally require nitro hydrocarbons as solvents.

[0089] The methods and devices not described in detail in the present invention are all prior art and will not be described in detail.

[0090] In order to better understand the present invention, the present invention is further specifically described below through the following examples, but it should not be understood as a limitation of the present invention. Some non-essential improvements and adjustments made by technicians in this field based on the above invention content are also considered to fall within the protection scope of the present invention.

[0091] Example 1

[0092] A method for preparing a photocatalyst sterilization, flame retardancy and sound insulation automobile carpet, the automobile carpet comprising a surface decoration layer, an insulation layer, a skeleton layer and an open-pore sponge rubber layer;

[0093] Flame retardant powder is added to the insulating layer, and photocatalyst powder is added to the sponge rubber layer;

[0094] The surface decoration layer, the insulating layer, the skeleton layer, and the sponge rubber layer are stacked together in order from top to bottom, and then placed in a setting machine for heating, and then molded to obtain a car carpet;

[0095] The preparation method of the photocatalyst sterilization, flame retardant and sound insulation automobile carpet specifically comprises the following steps in sequence:

[0096] 1) The PET fibers are sequentially opened, mixed, combed, laid, needled, rolled, raised, and rolled to form a surface decorative layer;

[0097] 2) Mix PE, PA and flame retardant powder evenly, pour into the mold after melting, and form an insulation layer after solidification;

[0098] 3) PET, PP and pure cotton are sequentially opened, mixed, combed, laid, needled and blanched to obtain a skeleton layer;

[0099] 4) preparing raw materials, including raw rubber, foaming agent, vulcanizing agent and photocatalyst powder, and then performing plastication and mixing in sequence, and then performing thin-pass plastication, and then performing vulcanization and foaming, and after completion, a sponge rubber layer is obtained;

[0100] 5) stacking the surface decoration layer, the insulating layer, the skeleton layer, and the sponge rubber layer in order from top to bottom, and then placing them in a setting machine for heating, and then performing compression molding to obtain a car carpet;

[0101] The method for preparing the sponge rubber layer specifically comprises the following steps performed in sequence:

[0102] 4.1) Prepare raw materials: Raw materials include raw rubber, foaming agent, vulcanizing agent, photocatalyst powder, activator, vulcanization accelerator and coagulant;

[0103] Plasticize the raw rubber;

[0104] In step 4.1), the raw materials include the following components in parts by mass: 96 parts of raw rubber, 0.8 parts of foaming agent, 0.7 parts of vulcanizing agent, 5 parts of photocatalyst powder, 0.9 parts of activator, 0.8 parts of vulcanization accelerator, and 0.7 parts of coagulant;

[0105] The raw rubber is nitrile rubber;

[0106] The foaming agent is potassium oleate;

[0107] The vulcanizing agent is sulfur;

[0108] The photocatalyst powder is nano titanium dioxide powder; the particle size of the photocatalyst powder is 90-100 nanometers;

[0109] The activator is a zinc oxide dispersion;

[0110] The vulcanization accelerator is diphenylguanidine;

[0111] The coagulant is sodium alginate;

[0112] 4.2) Mixing: Add the raw materials in step 4.1) into an internal mixer for mixing, and obtain a mixed material after mixing;

[0113] In step 4.2), the mixing temperature is 90°C-95°C, and the mixture is kneaded until the plasticity is 0.5-0.6;

[0114] 4.3) Thin-pass plastication: The mixed material obtained in step 4.2) is subjected to thin-pass plastication to obtain thin-pass sheets;

[0115] In step 4.3), the number of thin-pass mastication is 6 times, and then it is left for 2 days, and then it is masticated again for 3.5 minutes;

[0116] 4.4) Vulcanization and foaming: vulcanizing the thin sheet obtained in step 4.3), foaming and forming simultaneously during the vulcanization process, and obtaining a sponge rubber layer after cooling, wherein the photocatalyst particles are pre-embedded in the pore walls of the openings in the sponge rubber layer;

[0117] In step 4.4), the mixture is placed in a mold for vulcanization and foaming, the vulcanization temperature is 150°C-160°C, the vulcanization time is 20 minutes, and the vulcanization pressure is 3.0 MPa;

[0118] The foaming degree is controlled so that the thickness of the hole wall is 0.1-0.2 micrometers, and the maximum inner diameter of the opening is less than or equal to the particle size of the photocatalyst particles, so that the photocatalyst particles cannot fall out of the etched sponge rubber layer;

[0119] 4.5) Solvent etching: A solvent is applied to the sponge rubber layer, and the surface layer of the hole wall of the sponge rubber layer is dissolved and corroded by the solvent, so that a part of the volume of the photocatalyst particles pre-embedded in the hole wall is exposed to the outside, so that a part of the volume of the photocatalyst particles is exposed to the atmosphere and directly contacts with external bacteria, viruses, dirt, and odor, so that the strong oxidizing substances generated by the photocatalyst particles are directly contacted with external bacteria, viruses, dirt, and odor, and the remaining part of the volume of the photocatalyst particles is still pre-embedded in the hole wall, so that the hole wall fixes the remaining part of the volume of the photocatalyst particles to prevent the photocatalyst particles from falling from the car carpet;

[0120] After etching for a period of time, the sponge rubber layer is rinsed with ethanol to remove the residual solvent after the reaction, and then washed with water until the water is neutral, and then dried, and the etched sponge rubber layer is obtained after completion;

[0121] In step 4.5), when the raw rubber is nitrile rubber, the solvent used to dissolve and corrode the nitrile rubber is acetone, methyl ethyl ketone, chloroform, ethylene dichloride, trichloroethylene or ethyl acetate;

[0122] The coating method is to spray the solvent onto the sponge rubber layer;

[0123] The solvent is dissolved in ethanol, the mass percentage concentration of the solvent is controlled to be 10%-15%, and the solvent corrosion time is controlled to be 5-10 minutes, so that the surface thickness of the hole wall is dissolved and corroded to account for 25%-30% of the total thickness of the hole wall.

[0124] The above description of the disclosed embodiments enables one skilled in the art to implement or use the present invention. Various modifications to these embodiments will be apparent to one skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the present invention. Therefore, the present invention will not be limited to the embodiments shown herein, but rather to the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. A method for preparing a photocatalytic sterilization, flame retardant and sound-insulating automotive carpet, characterized in that: The automobile carpet comprises a surface decoration layer, an insulating layer, a skeleton layer and an open-pore sponge rubber layer; Flame retardant powder is added to the insulating layer, and photocatalyst powder is added to the sponge rubber layer; The surface decoration layer, the insulating layer, the skeleton layer and the sponge rubber layer are stacked together in order from top to bottom, and then placed in a molding machine for heating, and then molded to obtain a car carpet.

2. The method for preparing a photocatalytic sterilization, flame retardant and sound-insulating automotive carpet according to claim 1, characterized in that: Specifically, it includes the following steps in sequence: 1) The PET fibers are sequentially opened, mixed, combed, laid, needled, rolled, raised, and rolled to form a surface decorative layer; 2) Mix PE, PA and flame retardant powder evenly, pour into the mold after melting, and form an insulation layer after solidification; 3) PET, PP and pure cotton are sequentially opened, mixed, combed, laid, needled and blanched to obtain a skeleton layer; 4) preparing raw materials, including raw rubber, foaming agent, vulcanizing agent and photocatalyst powder, and then performing plastication and mixing in sequence, and then performing thin-pass plastication, and then performing vulcanization and foaming, and after completion, a sponge rubber layer is obtained; 5) The surface decoration layer, the insulating layer, the skeleton layer, and the sponge rubber layer are stacked together in order from top to bottom, and then placed in a molding machine for heating, and then molded to obtain a car carpet.

3. The method for preparing a photocatalytic sterilization, flame retardant and sound-insulating automotive carpet according to claim 1, characterized in that: The method for preparing the sponge rubber layer specifically comprises the following steps performed in sequence: 4.1) Prepare raw materials: Raw materials include raw rubber, foaming agent, vulcanizing agent, photocatalyst powder, activator, vulcanization accelerator and coagulant; Plasticize the raw rubber; 4.2) Mixing: Add the raw materials in step 4.1) into an internal mixer for mixing, and obtain a mixed material after mixing; 4.3) Thin-pass plastication: The mixed material obtained in step 4.2) is subjected to thin-pass plastication to obtain thin-pass sheets; 4.4) Vulcanization and foaming: vulcanizing the thin sheet obtained in step 4.3), foaming and forming simultaneously during the vulcanization process, and obtaining a sponge rubber layer after cooling, wherein the photocatalyst particles are pre-embedded in the pore walls of the openings in the sponge rubber layer; 4.5) Solvent etching: A solvent is applied to the sponge rubber layer, and the surface layer of the hole wall of the open hole in the sponge rubber layer is dissolved and corroded by the solvent, so that a part of the volume of the photocatalyst particles embedded in the hole wall is exposed to the outside, so that a part of the volume of the photocatalyst particles is exposed to the atmosphere and directly contacts with external bacteria, viruses, dirt, and odor, so that the strong oxidizing substances generated by the photocatalyst particles are directly contacted with external bacteria, viruses, dirt, and odor, and the remaining part of the volume of the photocatalyst particles is still embedded in the hole wall, so that the hole wall fixes the remaining part of the volume of the photocatalyst particles to prevent the photocatalyst particles from falling from the car carpet; After etching for a period of time, the sponge rubber layer is rinsed with ethanol to remove the residual solvent after the reaction, and then washed with water until the water is neutral, and then dried to obtain the etched sponge rubber layer.

4. The method for preparing a photocatalytic sterilization, flame retardant and sound-insulating automotive carpet according to claim 3, characterized in that: In step 4.1), the raw materials include the following components in parts by weight: 95-98 parts of raw rubber, 0.6-1.2 parts of foaming agent, 0.7-1.2 parts of vulcanizing agent, 2-5 parts of photocatalyst powder, 0.7-1.4 parts of activator, 0.7-1.4 parts of vulcanization accelerator, and 0.7-1.4 parts of coagulant; The raw rubber is nitrile rubber or styrene butadiene rubber; The foaming agent is potassium oleate; The vulcanizing agent is sulfur; The photocatalyst powder is nano titanium dioxide powder; the particle size of the photocatalyst powder is 70-100 nanometers; The activator is a zinc oxide dispersion; The vulcanization accelerator is diphenylguanidine; The coagulant is sodium alginate.

5. The method for preparing a photocatalytic sterilization, flame retardant and sound-insulating automotive carpet according to claim 3, characterized in that: In step 4.2), the mixing temperature is 90°C-100°C, and the mixture is kneaded until the plasticity is 0.5-0.

6.

6. The method for preparing a photocatalytic sterilization, flame retardant and sound-insulating automotive carpet according to claim 3, characterized in that: In step 4.3), the number of thin-pass mastication is 4-6 times, followed by a rest period of 1-3 days, and then thin-pass mastication again for 1.5-3.5 minutes.

7. The method for preparing a photocatalytic sterilization, flame retardant and sound-insulating automotive carpet according to claim 3, characterized in that: In step 4.4), the mixture is placed in a mold for vulcanization and foaming, the vulcanization temperature is 150°C-170°C, the vulcanization time is 10min-20min, and the vulcanization pressure is 2.5-3.5MPa; The foaming degree is controlled so that the thickness of the hole wall is 0.1-0.3 micrometers, and the maximum inner diameter of the opening is less than or equal to the particle diameter of the photocatalyst particles, so that the photocatalyst particles cannot fall out of the etched sponge rubber layer.

8. The method for preparing a photocatalytic sterilization, flame retardant and sound-insulating automotive carpet according to claim 3, characterized in that: In step 4.5), when the raw rubber is nitrile rubber, the solvent used to dissolve and corrode the nitrile rubber is acetone, methyl ethyl ketone, chloroform, ethylene dichloride, trichloroethylene or ethyl acetate; The coating method is to spray the solvent onto the sponge rubber layer or immerse the sponge rubber layer in the solvent; The solvent is dissolved in ethanol, the mass percentage concentration of the solvent is controlled to be 10%-25%, and the solvent corrosion time is controlled to be 5-20 minutes, so that the surface thickness of the hole wall is dissolved and corroded to account for 20%-40% of the total thickness of the hole wall.