Manufacturing method of green and environment-friendly spliced carpet with air purification function

Abstract

The invention relates to a manufacturing method of an environment-friendly spliced carpet with an air purification function, and belongs to the technical field of carpet weaving. The manufacturing method comprises the following steps: firstly, preparing a flame-retardant bacteriostatic agent, implanting the flame-retardant bacteriostatic agent and activated carbon into the carpet pile to form a functional layer, then coating EVA glue on the back surface of the tufting base carrying the functional layer, and carrying out heat treatment and drying to obtain the flame-retardant antibacterial carpet. Finally, the tufted base cloth and the carpet bottom blank coated with the green PU adhesive layer are compounded and then subjected to heat treatment, curing and cutting, and the green and environment-friendly spliced carpet with the air purification function is obtained. The carpet is green, environmentally friendly, free of peculiar smell, free of plasticizers, free of volatile organic solvents, good in antibacterial activity and good in inhibition effect on escherichia coli and staphylococcus aureus, the functional layer of the pile on the surface further has the air purification function, harmful gas such as formaldehyde in air can be adsorbed, the flame retardant property is excellent, and the carpet is worthy of popularization and application. The V-1 level can be reached.

Description

Technical Field

[0001] The invention belongs to the technical field of carpet weaving, and in particular relates to a method for manufacturing a green, environment-friendly, air-purifying patchwork carpet. Background Art

[0002] As a floor decoration material with a long history, carpets are widely used in many places such as homes, offices, hotels, shopping malls, etc. Its rich patterns, gorgeous colors and diverse materials not only add beauty to the space, but also have certain practical functions. The main materials of carpets in the prior art can be roughly divided into several categories, such as wool, pure wool non-woven, chemical fiber, synthetic fiber flocking, plastic and straw. Each material has different prices and characteristics due to its different physical and chemical properties, but generally has the following disadvantages. First, the pile structure on the surface of the carpet is easy to breed bacteria, so it needs to be cleaned and maintained regularly. After multiple cleaning and maintenance, the carpet pile often falls off and fades, which greatly increases the maintenance cost of the carpet and reduces the service life of the carpet. In addition, organic solvents may need to be used in the carpet manufacturing process. If these organic solvents are not removed in time, they will evaporate during use, posing a considerable threat to people's health. In addition, conventional carpets are not flame retardant and are mostly flammable. They are easy to catch fire when they come into contact with cigarette ash and cigarette butts, posing a safety hazard. Summary of the invention

[0003] The purpose of the present invention is to provide a green and environmentally friendly method for manufacturing a mosaic carpet with air purification function, by implanting activated carbon and a self-made composite functional agent in the carpet pile to provide the carpet with flame retardancy and antibacterial properties, and can absorb harmful gases such as formaldehyde in the air to purify the air.

[0004] The purpose of the present invention can be achieved through the following technical solutions: A method for manufacturing a green and environmentally friendly carpet tile with air purification function comprises the following steps: Step 1: Mix 2-aminoethylpyridine, epichlorohydrin and chloroform in a three-necked flask, install a condenser and a thermometer, turn on the magnetic stirring, add hydrochloric acid dropwise to the three-necked flask at room temperature, and then react at 50°C for 3h. After the reaction is completed, rotary evaporation is performed to obtain intermediate 1; Step 2: neopentyl glycol and chloroform were mixed in a three-necked flask, a condenser and a thermometer were installed, magnetic stirring was turned on, phosphorus oxychloride was added dropwise to the three-necked flask at 60°C using a high-pressure dropping pump, and after the addition was completed, the reaction was carried out at 60°C for 2h. After the reaction was completed, intermediate 2 was obtained by rotary evaporation; Step 3: Mix intermediate 1, triethylamine and chloroform in a three-necked flask, install a condenser and a thermometer, turn on the magnetic stirring, and add the chloroform solution of intermediate 2 to the three-necked flask dropwise at 60°C using a high-pressure dropping pump, and then react at 60°C for 4 hours. After the reaction is completed, rotary evaporation is performed to obtain intermediate 3; Step 4: Mix the intermediate 3, N,N-dimethyldodecylamine and ethanol in a three-necked flask, install a condenser and a thermometer, start magnetic stirring, and react at 75°C for 12 hours. After the reaction is completed, remove the solvent by rotary evaporation, wash the product with n-hexane, and then recrystallize with acetone to obtain a flame retardant and antibacterial agent; Step 5: Pile yarn is implanted on the surface of the tufted base fabric to form the carpet pile, and activated carbon and flame retardant and antibacterial agent are implanted in the carpet pile to form a functional layer, and then EVA glue is coated on the back of the carpet pile, and heat treatment and drying are performed; Step 6: Coat a green PU adhesive layer on the surface of the green non-woven fabric, then cover it with a glass fiber mesh and coat it with a second layer of green PU adhesive layer to obtain a carpet base; Step 7: Compound the EVA adhesive layer of the tufted base fabric with the carpet base, then solidify the green PU adhesive layer through heat treatment, cool and roll to set the shape, and finally cut the carpet with a cutting machine to obtain a green and environmentally friendly patchwork carpet with air purification function.

[0005] Furthermore, the hydrochloric acid in the first step is a 30% by mass hydrogen chloride aqueous solution.

[0006] Furthermore, the dosage ratio of 2-aminoethylpyridine, epichlorohydrin, chloroform and hydrochloric acid used in the first step is: 0.1 mol: 0.2-0.22 mol: 80-100 mL: 10-15 mL.

[0007] Furthermore, the dosage ratio of neopentyl glycol, chloroform and phosphorus oxychloride used in the second step is: 0.1 mol: 80-100 mL: 0.12-0.15 mol.

[0008] Furthermore, the chloroform solution of intermediate 2 in the third step is prepared from 0.07 mol of intermediate 2 and 30 mL of chloroform.

[0009] Furthermore, the usage ratio of the intermediate 1, triethylamine, chloroform, and the chloroform solution of the intermediate 2 used in the third step is 0.07 mol: 0.1-0.13 mol: 100-120 mL: 55.5 g.

[0010] Furthermore, the usage ratio of the intermediate 3, N,N-dimethyldodecylamine and ethanol used in the fourth step is 0.05 mol: 0.1-0.12 mol: 80-100 mL.

[0011] Furthermore, the temperature condition of the heat treatment in the fifth step is 120-180°C.

[0012] Furthermore, in the sixth step, the thickness of the green PU adhesive layer is 8-12 mm.

[0013] Furthermore, the temperature of the heat treatment in the seventh step is 140-190°C.

[0014] Beneficial effects of the present invention: The invention uses flame retardant and antibacterial agent, activated carbon, green non-woven fabric, glass fiber mesh, pile yarn, tufted base fabric, EVA glue and green PU glue as raw materials to prepare a green and environmentally friendly mosaic carpet with air purification function; the mosaic carpet of the invention has a double-layer green PU glue layer, so it has good elasticity and has the functions of purifying air and killing bacteria.

[0015] The invention uses 2-aminoethylpyridine and epichlorohydrin as raw materials, and carries out a ring-opening reaction between an amino group and an epoxy group under acidic conditions to obtain an intermediate 1; uses neopentyl glycol and phosphorus oxychloride as raw materials, and carries out an esterification reaction to obtain an intermediate 2; then, the hydroxyl group of the intermediate 1 and the intermediate 2 are subjected to an esterification reaction under the condition that triethylamine is an acid-binding agent to obtain an intermediate 3; finally, the chlorine atom of the intermediate 3 is subjected to a quaternary ammonium salt reaction with N,N-dimethyldodecylamine to obtain a flame retardant and antibacterial agent with a double long-chain alkyl structure; the flame retardant and antibacterial agent of the invention has a pyridine quaternary ammonium salt structure of a double long-chain alkyl group, and the quaternary ammonium salt structure synergistically acts with pyridine to give the flame retardant and antibacterial agent excellent The flame retardant and antibacterial agent has antibacterial properties. The cationic charge on its polar head group has a strong adsorption tendency, can adsorb bacterial cell walls and pierce the bacterial cell membrane through the long-chain alkyl to achieve an antibacterial effect. In addition, the flame retardant and antibacterial agent also has a double-ended phosphate structure, which can form a non-flammable and dense protective carbon layer during combustion to prevent further combustion of the substrate. During the combustion process, the double-ended phosphate structure of the flame retardant and antibacterial agent can also decompose to produce PO· free radicals, which can react with H· free radicals and OH· free radicals produced by combustion, thereby interrupting the chain reaction of combustion and preventing the spread of flames. Therefore, the flame retardant and antibacterial agent of the present invention has good antibacterial properties and flame retardant properties.

[0016] The green and environmentally friendly air-purifying patchwork carpet backing of the present invention is mainly made of PU, which does not contain benzene, non-volatile organic solvents, or plasticizers, and is green, environmentally friendly and odorless. In addition, the carpet backing of the present invention is lighter than traditional carpets, and can effectively reduce energy consumption during transportation, saving manpower and material resources. In addition, the functional layer of the carpet pile of the present invention contains activated carbon and flame retardant and antibacterial agents, and has air purification and antibacterial and mildew-proof functions. The novel green backing can also give consumers a refreshing sensory experience, and has good market prospects. DETAILED DESCRIPTION

[0017] 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. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. 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.

[0018] Example 1

[0019] A flame retardant and antibacterial agent is prepared by the following steps: Step 1: 0.1 mol 2-aminoethylpyridine, 0.2 mol epichlorohydrin, and 80 mL chloroform were mixed in a container, stirred evenly, and then 10 mL of a 30% by mass aqueous solution of hydrogen chloride was added to the container at room temperature, and then reacted at 50°C for 3 h. After the reaction was completed, the intermediate 1 was obtained by rotary evaporation; Step 2: 0.1 mol of neopentyl glycol and 80 mL of chloroform were mixed in a container, stirred evenly, and then 0.12 mol of phosphorus oxychloride was added dropwise to the container at 60°C. After the addition was completed, the mixture was reacted at 60°C for 2 h. After the reaction was completed, the intermediate 2 was obtained by rotary evaporation. Step 3: 0.07 mol of intermediate 1, 0.1 mol of triethylamine and 100 mL of chloroform were mixed in a container, stirred evenly, and then 55.5 g of chloroform solution of intermediate 2 was added dropwise to the container at a temperature of 60°C, and then reacted at 60°C for 4 hours. After the reaction was completed, intermediate 3 was obtained by rotary evaporation. The chloroform solution of intermediate 2 used in this step was prepared from 0.07 mol of intermediate 2 and 30 mL of chloroform; Step 4: Mix 0.05 mol of intermediate 3, 0.1 mol of N,N-dimethyldodecylamine and 80 mL of ethanol in a container, stir evenly, and react at 75°C for 12 hours. After the reaction, remove the solvent by rotary evaporation, wash the product with n-hexane, and then recrystallize with acetone to obtain a flame retardant and antibacterial agent.

[0020] Example 2

[0021] A flame retardant and antibacterial agent is prepared by the following steps: Step 1: 0.1 mol 2-aminoethylpyridine, 0.21 mol epichlorohydrin, and 90 mL chloroform were mixed in a container, stirred evenly, and then 12.5 mL of a 30% by mass aqueous solution of hydrogen chloride was added to the container at room temperature, and then reacted at a temperature of 50°C for 3 h. After the reaction was completed, the intermediate 1 was obtained by rotary evaporation; Step 2: 0.1 mol of neopentyl glycol and 90 mL of chloroform were mixed in a container, stirred evenly, and then 0.135 mol of phosphorus oxychloride was added dropwise to the container at 60°C. After the addition was completed, the mixture was reacted at 60°C for 2 hours. After the reaction was completed, the intermediate 2 was obtained by rotary evaporation; Step 3: 0.07 mol of intermediate 1, 0.115 mol of triethylamine and 110 mL of chloroform were mixed in a container, stirred evenly, and then 55.5 g of chloroform solution of intermediate 2 was added dropwise to the container at a temperature of 60°C, and then reacted at 60°C for 4 hours. After the reaction was completed, intermediate 3 was obtained by rotary evaporation. The chloroform solution of intermediate 2 used in this step was prepared from 0.07 mol of intermediate 2 and 30 mL of chloroform; Step 4: Mix 0.05 mol of intermediate 3, 0.11 mol of N,N-dimethyldodecylamine and 90 mL of ethanol in a container, stir evenly, and react at 75°C for 12 hours. After the reaction, remove the solvent by rotary evaporation, wash the product with n-hexane, and then recrystallize with acetone to obtain a flame retardant and antibacterial agent.

[0022] Example 3

[0023] A flame retardant and antibacterial agent is prepared by the following steps: Step 1: 0.1 mol 2-aminoethylpyridine, 0.22 mol epichlorohydrin, and 100 mL chloroform were mixed in a container, stirred evenly, and then 15 mL of a 30% by mass aqueous solution of hydrogen chloride was added to the container at room temperature, and then reacted at a temperature of 50°C for 3 hours. After the reaction was completed, the intermediate 1 was obtained by rotary evaporation; Step 2: 0.1 mol of neopentyl glycol and 100 mL of chloroform were mixed in a container, stirred evenly, and then 0.15 mol of phosphorus oxychloride was added dropwise to the container at 60°C. After the addition was completed, the mixture was reacted at 60°C for 2 h. After the reaction was completed, the intermediate 2 was obtained by rotary evaporation; Step 3: 0.07 mol of intermediate 1, 0.13 mol of triethylamine and 120 mL of chloroform were mixed in a container, stirred evenly, and then 55.5 g of chloroform solution of intermediate 2 was added dropwise to the container at a temperature of 60°C, and then reacted at 60°C for 4 hours. After the reaction was completed, intermediate 3 was obtained by rotary evaporation. The chloroform solution of intermediate 2 used in this step was prepared from 0.07 mol of intermediate 2 and 30 mL of chloroform; Step 4: Mix 0.05 mol of intermediate 3, 0.12 mol of N,N-dimethyldodecylamine and 100 mL of ethanol in a container, stir evenly, and react at 75°C for 12 hours. After the reaction, remove the solvent by rotary evaporation, wash the product with n-hexane, and then recrystallize with acetone to obtain a flame retardant and antibacterial agent.

[0024] Experimental Example 1 The flame retardant and antibacterial agent obtained in Examples 1-3 was tested for antibacterial performance according to the standard QB / T 2850-2007, and the antibacterial rates of Escherichia coli and Staphylococcus aureus were tested respectively. The test results are shown in Table 1: Table 1

[0025] It can be seen from Table 1 that the flame retardant and antibacterial agent of the present invention can have a good inhibitory effect on common Escherichia coli and Staphylococcus aureus, with an inhibition rate of more than 98% on Escherichia coli and more than 94% on Staphylococcus aureus. Therefore, compared with the pile of traditional carpets, the functional layer of the flame retardant and antibacterial agent implanted in the carpet of the present invention is not only less likely to breed bacteria, but also has antibacterial and mildew-proof functions.

[0026] Example 4

[0027] A green and environmentally friendly carpet tile with air purification function is made by the following steps: The first step: implanting pile yarns on the surface of the tufted base fabric to form carpet pile, and implanting activated carbon and the flame retardant and antibacterial agent obtained in Example 1 into the carpet pile to form a functional layer, and then coating the back of the carpet pile with EVA glue, and heat-treating and drying at a temperature of 120°C; Step 2: Coat an 8mm green PU adhesive layer on the surface of the green non-woven fabric, then cover it with a glass fiber mesh and coat it with a second 8mm green PU adhesive layer to obtain a carpet base; The third step: compound the EVA adhesive layer of the tufted base fabric with the carpet base, then heat treat and solidify the green PU adhesive layer at 140°C, cool and roll to set the shape, and finally use a cutting machine to cut the carpet to obtain a green and environmentally friendly patchwork carpet with air purification function.

[0028] Example 5

[0029] A green and environmentally friendly carpet tile with air purification function is made by the following steps: The first step: implanting pile yarns on the surface of the tufted base fabric to form carpet pile, and implanting activated carbon and the flame retardant and antibacterial agent obtained in Example 2 into the carpet pile to form a functional layer, and then coating the back of the carpet pile with EVA glue, and heat-treating and drying at a temperature of 150°C; Step 2: Coat a 10mm green PU adhesive layer on the surface of the green non-woven fabric, then cover it with a glass fiber mesh and coat it with a second 10mm green PU adhesive layer to obtain a carpet base; Step 3: Compound the EVA adhesive layer of the tufted base fabric with the carpet base, then heat treat and solidify the green PU adhesive layer at 165°C, cool and roll to set the shape, and finally cut the carpet with a cutting machine to obtain a green and environmentally friendly patchwork carpet with air purification function.

[0030] Example 6

[0031] A green and environmentally friendly carpet tile with air purification function is made by the following steps: The first step: implanting pile yarns on the surface of the tufted base fabric to form carpet pile, and implanting activated carbon and the flame retardant and antibacterial agent obtained in Example 3 into the carpet pile to form a functional layer, and then coating the back of the carpet pile with EVA glue, and heat-treating and drying at a temperature of 180°C; Step 2: Coat a 12mm green PU adhesive layer on the surface of the green non-woven fabric, then cover it with a glass fiber mesh and coat it with a second 12mm green PU adhesive layer to obtain a carpet base; The third step: compound the EVA adhesive layer of the tufted base fabric with the carpet base, then heat treat and solidify the green PU adhesive layer at 190°C, cool and roll to set the shape, and finally use a cutting machine to cut the carpet to obtain a green and environmentally friendly patchwork carpet with air purification function.

[0032] Comparative Example 1 The "flame retardant and antibacterial agent obtained in Example 3" used in Example 6 is removed, and the remaining steps remain unchanged.

[0033] Comparative Example 2 This comparative example is a flame-retardant carpet sold by Shanghai Boyi Carpet Co., Ltd.

[0034] The green and environmentally friendly air purification carpet tiles prepared in Examples 4-6 and Comparative Example 1 and the flame-retardant carpet sold by Shanghai Boyi Carpet Co., Ltd. in Comparative Example 2 were tested for their combustion performance at a 45° inclination angle using GB / T14768-1993. The test structure is shown in Table 2: Table 2

[0035] It can be seen from Table 2 that the green and environmentally friendly air purification function mosaic carpet of the present invention has excellent flame retardant properties, which can reach V-1 level, and is better than other flame retardant carpets on the market. The carpet prepared in Comparative Example 1 without the flame retardant and antibacterial agent of the present invention does not have flame retardant properties, indicating that the implantation of the flame retardant and antibacterial agent of the present invention can give the carpet good flame retardancy. In addition, the green and environmentally friendly air purification function mosaic carpet of the present invention also has antibacterial properties, is green and environmentally friendly, and is lightweight, which is conducive to promotion.

[0036] The above contents are merely examples and explanations of the present invention. Those skilled in the art may make various modifications or additions to the specific embodiments described or replace them in a similar manner. As long as they do not deviate from the invention or exceed the scope defined by the claims, they shall all fall within the protection scope of the present invention.

Claims

1. A method for manufacturing a green and environmentally friendly carpet tile with air purification function, comprising the following steps: Step 1: 2-aminoethylpyridine, epichlorohydrin and chloroform were mixed in a container, stirred evenly, and then hydrochloric acid was added to the container at room temperature, and then reacted at 50°C for 3h to obtain intermediate 1; Step 2: neopentyl glycol and chloroform are mixed in a container, phosphorus oxychloride is added to the container at a temperature of 60°C, and then reacted at a temperature of 60°C for 2h to obtain intermediate 2; Step 3: Mix intermediate 1, triethylamine and chloroform in a container, add the chloroform solution of intermediate 2 into the container at 60°C, and then react at 60°C for 4h to obtain intermediate 3; Step 4: Mix the intermediate 3, N,N-dimethyldodecylamine and ethanol in a container and react at 75°C for 12 hours to obtain a flame retardant and antibacterial agent; Step 5: Pile yarn is implanted on the surface of the tufted base fabric to form the carpet pile, and activated carbon and flame retardant and antibacterial agent are implanted in the carpet pile to form a functional layer, and then EVA glue is coated on the back of the carpet pile, and heat treatment and drying are performed; Step 6: Coat a green PU adhesive layer on the surface of the green non-woven fabric, then cover it with a glass fiber mesh and coat it with a second layer of green PU adhesive layer to obtain a carpet base; Step 7: Compound the EVA adhesive layer of the tufted base fabric with the carpet base, then solidify the green PU adhesive layer through heat treatment, cool and roll to set the shape, and finally cut the carpet with a cutting machine to obtain a green and environmentally friendly patchwork carpet with air purification function.

2. The method for manufacturing a green and environmentally friendly carpet tile with air purification function according to claim 1, characterized in that: The hydrochloric acid in the first step is a 30% by mass aqueous solution of hydrogen chloride.

3. The method for manufacturing a green and environmentally friendly carpet tile with air purification function according to claim 1, characterized in that: The dosage ratio of 2-aminoethylpyridine, epichlorohydrin, chloroform and hydrochloric acid used in the first step is: 0.1 mol: 0.2-0.22 mol: 80-100 mL: 10-15 mL.

4. The method for manufacturing a green and environmentally friendly carpet tile with air purification function according to claim 1, characterized in that: The dosage ratio of neopentyl glycol, chloroform and phosphorus oxychloride used in the second step is: 0.1 mol: 80-100 mL: 0.12-0.15 mol.

5. The method for manufacturing a green and environmentally friendly carpet tile with air purification function according to claim 1, characterized in that: The chloroform solution of intermediate 2 in the third step is prepared from 0.07 mol of intermediate 2 and 30 mL of chloroform.

6. The method for manufacturing a green and environmentally friendly carpet tile with air purification function according to claim 1, characterized in that: The usage ratio of the intermediate 1, triethylamine, chloroform and the chloroform solution of the intermediate 2 used in the third step is 0.07 mol: 0.1-0.13 mol: 100-120 mL: 55.5 g.

7. The method for manufacturing a green and environmentally friendly carpet tile with air purification function according to claim 1, characterized in that: The usage ratio of the intermediate 3, N,N-dimethyldodecylamine and ethanol used in the fourth step is 0.05 mol: 0.1-0.12 mol: 80-100 mL.

8. The method for manufacturing a green and environmentally friendly carpet tile with air purification function according to claim 1, characterized in that: The temperature condition of the heat treatment in the fifth step is 120-180°C.

9. The method for manufacturing a green and environmentally friendly carpet tile with air purification function according to claim 1, characterized in that: In the sixth step, the thickness of the green PU adhesive layer is 8-12mm.

10. The method for manufacturing a green and environmentally friendly carpet tile with air purification function according to claim 1, characterized in that: The temperature of the heat treatment in the seventh step is 140-190°C.

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