Lightweight automotive carpet and preparation method thereof

Abstract

The invention relates to the technical field of automobile carpets, in particular to a light-weight automobile carpet and a preparation method thereof.By the adoption of the structure of an antibacterial polyurethane sponge middle layer and an antibacterial wear-resisting PET non-woven fabric surface layer, it is guaranteed that the carpet has good performance, meanwhile, the light-weight design can be achieved, polyurethane sponge has the advantages of being low in density and light in weight, and the carpet has a good application prospect. The PET non-woven fabric is relatively light, so that the weight of the whole carpet is reduced, the overall weight of an automobile is reduced, the fuel economy of the automobile is improved, the energy consumption and the exhaust emission are reduced, and the carpet conforms to the development trend of light weight of modern automobiles. The light-weight automobile carpet has the advantages of being antibacterial, wear-resistant and light in weight, the preparation method is scientific and reasonable, industrial production is easy to achieve, and the light-weight automobile carpet is worthy of popularization along with continuous development of the automobile industry and improvement of the requirements of consumers for the quality of automobile interiors. The light-weight automobile carpet with excellent performance has a wide application prospect in the automobile market.

Description

Technical Field

[0001] The present invention relates to the technical field of automotive carpets, and particularly relates to a lightweight automotive carpet and a preparation method thereof. Background Art

[0002] In the process of the continuous development of the automotive industry, the quality and performance of automotive interiors have increasingly attracted the attention of consumers and automotive manufacturers. As an important part of automotive interiors, the performance of automotive carpets directly affects the comfort of passengers and drivers, the hygiene of the interior environment, and the overall quality of the vehicle. Traditional automotive carpets are usually made of ordinary sponge or fiber materials, which have obvious deficiencies in antibacterial performance. In the relatively enclosed, warm and humid environment inside the vehicle, the carpets are prone to breed bacteria, molds and other microorganisms, which will not only produce unpleasant odors, but also pose potential threats to the health of passengers and drivers. In addition, the wear resistance of traditional automotive carpets is also poor. During long-term use, they are prone to wear, pilling and other phenomena, which affect the aesthetics and service life of the carpets and increase the usage cost of consumers.

[0003] With the continuous advancement of the development trend of automotive lightweighting, the relatively heavy weight of traditional automotive carpets has also become one of the factors restricting the improvement of automotive fuel economy and environmental protection performance. Therefore, it is of great practical significance to develop an automotive carpet with excellent antibacterial performance, good wear resistance and the ability to achieve lightweighting. At present, although there are already some automotive carpets with antibacterial or wear-resistant functions on the market, these products often have many defects. Some antibacterial automotive carpets only add simple antibacterial agents on the surface layer, with poor and non-persistent antibacterial effects and limited antibacterial ranges, and cannot effectively inhibit bacteria in the intermediate layer and deeper layers; while some wear-resistant automotive carpets achieve the improvement of wear resistance by increasing the thickness of the material or adding a large amount of wear-resistant fillers, which not only increases the weight of the carpet, but also may affect the softness and comfort of the carpet. In addition, the existing preparation processes of automotive carpets are relatively complex, with low production efficiency and it is difficult to ensure the consistency of product quality. Therefore, how to improve the deficiencies of the above existing technologies has become an urgent problem for those skilled in the art to solve. Summary of the Invention

[0004] Technical Problems to be Solved

[0005] In view of the above-mentioned shortcomings of the existing technology, the present invention provides a lightweight automotive carpet and a preparation method thereof, which can effectively solve the problems of poor antibacterial performance, poor wear resistance and relatively large weight of the automotive carpets in the existing technology.

[0006] Technical Solutions

[0007] To achieve the above purposes, the present invention is realized through the following technical solutions:

[0008] A lightweight automotive carpet, which is composed of the following structure: an antibacterial polyurethane sponge intermediate layer and an antibacterial and wear-resistant PET non-woven fabric surface layer;

[0009] The antibacterial polyurethane sponge intermediate layer is obtained by subjecting polyurethane sponge to antibacterial modification treatment;

[0010] The antibacterial and wear-resistant PET non-woven fabric surface layer is prepared from PET chips, silver-loaded carbon nanotube antibacterial agent and wear-resistant modification components as the main raw materials.

[0011] Furthermore, the preparation method of the antibacterial polyurethane sponge intermediate layer is as follows:

[0012] S1. Weigh 70 - 80 g of polyether polyol and 20 - 30 g of polyester polyol and pour them into a flask. Then, successively add 0.3 - 0.4 g of triethylenediamine, 0.1 - 0.2 g of organic zinc catalyst, 1.2 - 1.5 g of foam stabilizer and 3 - 5 g of deionized water. After quickly stirring evenly, add 48 - 50 g of diphenylmethane diisocyanate, stir at high speed until the mixture turns white, then pour it into a mold and place it in an oven at 50 °C for static foaming for 30 - 50 min. The obtained product is denoted as polyurethane sponge;

[0013] S2. Weigh 0.1 - 0.2 g of dopamine hydrochloride and 0.2 - 0.3 g of sodium periodate and add them to 50 mL of sodium acetate buffer solution. After stirring and dispersing, immerse the polyurethane sponge and let it stand for 30 min. Take it out, drain it, ultrasonically clean it with deionized water for 5 - 6 min and squeeze out the water. The obtained product is denoted as modified polyurethane sponge;

[0014] S3. Immerse the modified polyurethane sponge in silver nitrate solution and let it stand under ultraviolet light at 365 nm for 30 min. Take it out, drain it, ultrasonically clean it with deionized water for 5 - 6 min and squeeze out the water. After drying treatment, the obtained product is the antibacterial polyurethane sponge intermediate layer.

[0015] Furthermore, the method of quickly stirring evenly in S1 is to stir at a speed of 600 - 800 r / min for 10 min. The rotation speed of high-speed stirring in S1 is 1000 - 1200 r / min, and the thickness of the polyurethane sponge in S1 is 5 - 10 mm.

[0016] Furthermore, the pH value of the sodium acetate buffer solution in S2 is 5.5. The method of stirring and dispersing in S2 is to stir at a speed of 500 - 600 r / min for 10 min. The concentration of the silver nitrate solution in S3 is 0.1 mol / L, and the method of drying treatment in S3 is to dry it in an oven at 50 - 55 °C for 6 h.

[0017] Furthermore, the preparation steps of the silver-loaded carbon nanotube antibacterial agent are as follows:

[0018] Step 1: Immerse 1 - 2 g of multi - walled carbon nanotubes into 40 - 50 mL of nitric acid solution, perform oxidative reflux at 60 °C for 30 min, cool to room temperature, filter to remove the filtrate, wash with deionized water until neutral, and finally dry in an oven at 120 °C for 4 h. The obtained product is denoted as acid - treated multi - walled carbon nanotubes;

[0019] Step 2: Immerse 1 - 2 g of acid - treated multi - walled carbon nanotubes into 200 mL of silver nitrate solution with a concentration of 0.2 mol / L, perform ultrasonic dispersion, adjust the pH value to 6 - 7, and let it stand for reaction for 3 - 4 h. After centrifugation, wash the precipitate with deionized water 5 - 6 times, dry at 100 °C for 3 - 4 h, and then grind through a 100 - mesh sieve. The obtained product is denoted as silver - loaded carbon nanotube antibacterial agent.

[0020] Furthermore, in Step 1, the concentration of the nitric acid solution is 3 mol / L. In Step 2, the method of ultrasonic dispersion is to perform ultrasonic dispersion at a frequency of 30 kHz for 15 - 20 min. In Step 2, the pH value is adjusted by dropping ammonia water solution. In Step 2, the method of centrifugation is to centrifuge at a speed of 6000 r / min for 5 min.

[0021] Furthermore, the preparation method of the wear - resistant modification component is as follows:

[0022] Weigh 5 - 8 g of nano - silica and 9 - 10 g of polytetrafluoroethylene micro - powder, pour them into a ball mill, ball - mill at a speed of 500 r / min for 5 min, then add 1 - 2 g of silane coupling agent KH - 550 and 1 - 2 g of calcium stearate, and continue ball - milling for 10 min. The obtained product is the wear - resistant modification component.

[0023] Furthermore, the preparation method of the antibacterial and wear - resistant PET non - woven fabric surface layer is as follows:

[0024] Pour 100 g of PET chips, 3 - 4 g of silver - loaded carbon nanotube antibacterial agent, 3 - 5 g of wear - resistant modification component, and 1 - 2 g of polyvinylpyrrolidone into a mixer, perform mixing at a temperature of 270 - 290 °C for 5 - 10 min, and obtain the antibacterial and wear - resistant PET non - woven fabric surface layer through a melt - blown spinning machine.

[0025] Furthermore, in the preparation method of the antibacterial and wear - resistant PET non - woven fabric surface layer, the temperature of melt - blown spinning is 280 - 300 °C, the receiving distance of the melt - blown cloth is 200 mm, the hot - air temperature of hot - air traction is 330 - 350 °C, the traction air pressure is 0.2 - 0.3 MPa, and the thickness of the antibacterial and wear - resistant PET non - woven fabric surface layer is 0.5 - 0.8 mm.

[0026] A preparation method of a lightweight automotive carpet, and the preparation method is as follows:

[0027] Lay the surface layer of antibacterial and wear-resistant PET non-woven fabric flat on the surface of the middle layer of antibacterial polyurethane sponge, and thermally press and form the combination of the two through a hot pressing process under a pressure of 220 - 230 °C. The resulting carpet with upper, middle, and lower layers being the surface layer of antibacterial and wear-resistant PET non-woven fabric, the middle layer of antibacterial polyurethane sponge, and the surface layer of antibacterial and wear-resistant PET non-woven fabric is a lightweight automotive carpet.

[0028] Beneficial effects

[0029] The present invention provides a lightweight automotive carpet and its preparation method. Compared with the existing well-known technologies, the present invention has the following beneficial effects:

[0030] 1. Through the antibacterial modification treatment of polyurethane sponge and the addition of silver-loaded carbon nanotube antibacterial agent in the PET non-woven fabric surface layer, the present invention endows the carpet with excellent antibacterial properties from two aspects of the middle layer and the surface layer. The silver-loaded carbon nanotube antibacterial agent has a strong antibacterial ability, which can effectively inhibit the growth and reproduction of microorganisms such as bacteria and molds, provide reliable sanitation guarantee for the vehicle interior environment, reduce the odor and health hazards caused by the growth of microorganisms, improve the air quality in the vehicle, and ensure the health of the driver and passengers; while the antibacterial polyurethane sponge middle layer is modified with dopamine hydrochloride and sodium periodate on the polyurethane sponge, and then treated with silver nitrate solution assisted by ultraviolet light to form a stable antibacterial structure, which can further enhance the antibacterial effect of the middle layer, and cooperate with the surface layer antibacterial agent to achieve all-round antibacterial protection.

[0031] 2. The wear-resistant modification component in the present invention is prepared by a ball milling process from nano-silica, polytetrafluoroethylene micropowder, silane coupling agent KH-550, and calcium stearate. The addition of nano-silica and polytetrafluoroethylene micropowder can improve the hardness and wear resistance of the material, while silane coupling agent KH-550 and calcium stearate help to enhance the binding force between the components, enabling the wear-resistant modification component to be better dispersed in the PET non-woven fabric, effectively improving the wear resistance of the PET non-woven fabric surface layer, prolonging the service life of the carpet, reducing the damage and replacement frequency of the carpet caused by wear, and lowering the usage cost.

[0032] 3. The present invention adopts a structure with an antibacterial polyurethane sponge intermediate layer and an antibacterial and wear-resistant PET non-woven fabric surface layer. While ensuring good performance of the carpet, it can achieve lightweight design. The polyurethane sponge has the characteristics of low density and light weight, and the PET non-woven fabric is also relatively light. This combination reduces the weight of the entire carpet, helps to reduce the overall weight of the vehicle, improves the fuel economy of the vehicle, reduces energy consumption and exhaust emissions, and conforms to the development trend of modern vehicle lightweighting. The lightweight automotive carpet in the present invention not only has the advantages of antibacterial, wear-resistant, and lightweight, but also has a scientific and reasonable preparation method and is easy to realize industrial production. With the continuous development of the automotive industry and the improvement of consumers' requirements for the quality of automotive interiors, this lightweight automotive carpet with excellent performance has broad application prospects in the automotive market. Detailed implementation manners

[0033] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below. Obviously, the described embodiments are some, but not all, of the embodiments of the present invention. All other embodiments obtained by those of ordinary skill in the art based on the embodiments of the present invention without creative efforts shall fall within the protection scope of the present invention.

[0034] The present invention will be further described below with reference to embodiments.

[0035] The sources of some components in the examples and comparative examples are as follows:

[0036] Polyether polyol, molecular weight 4800, industrial pure, Wanhua Chemical Group Co., Ltd.

[0037] Polyester polyol, molecular weight 3000 ± 200, industrial pure, Wanhua Chemical Group Co., Ltd.

[0038] Triethylenediamine, model A33, industrial pure, Sinopharm Chemical Reagent Co., Ltd.

[0039] Organic zinc catalyst, model T52, industrial pure, Guangzhou Yourun Synthetic Materials Co., Ltd.

[0040] Foam stabilizer, model L580, industrial pure, Sinopharm Chemical Reagent Co., Ltd.

[0041] Diphenylmethane diisocyanate, industrial pure, Sinopharm Chemical Reagent Co., Ltd.

[0042] Hydrochloric acid dopamine, analytical pure, Wuhan Huashun Biotechnology Co., Ltd.

[0043] Sodium periodate, analytical pure, Wuhan Huashun Biotechnology Co., Ltd.

[0044] Sodium acetate, analytical reagent, Wuhan Huashun Biotechnology Co., Ltd.;

[0045] Silver nitrate, analytical reagent, Wuhan Huashun Biotechnology Co., Ltd.;

[0046] Multi-walled carbon nanotubes, Shenzhen Duowei New Materials Co., Ltd.;

[0047] Ammonia water, Jinan Xinchen Chemical Co., Ltd.;

[0048] Nano-silica, Weifang Sanjia Chemical Co., Ltd.;

[0049] Polytetrafluoroethylene micropowder, Dongguan Jinqun Plastic Co., Ltd.;

[0050] Silane coupling agent KH-550, Shandong Rongsheng New Materials Co., Ltd.;

[0051] Calcium stearate, Wuhan Xindongyi Chemical Co., Ltd.;

[0052] PET chips, Shanghai Changshi Plastic Co., Ltd.;

[0053] Example 1

[0054] A lightweight automotive carpet in this example consists of the following structure: an antibacterial polyurethane sponge intermediate layer and an antibacterial and wear-resistant PET non-woven fabric surface layer;

[0055] The antibacterial polyurethane sponge intermediate layer is prepared by subjecting polyurethane sponge to antibacterial modification treatment. Its preparation method is as follows:

[0056] S1. Weigh 70 g of polyether polyol and 20 g of polyester polyol and pour them into a flask. Then, successively add 0.3 g of triethylenediamine, 0.1 g of organic zinc catalyst, 1.2 g of foam stabilizer, and 3 g of deionized water. Stir at a speed of 600 r / min for 10 min, then add 48 g of diphenylmethane diisocyanate. Stir at a high speed of 1000 r / min until the mixture turns white, then pour it into a mold with a thickness of 5 mm and place it in an oven at 50 °C for 30 min to stand and foam. The obtained product is denoted as polyurethane sponge;

[0057] S2. Weigh 0.1 g of dopamine hydrochloride and 0.2 g of sodium periodate and add them to 50 mL of sodium acetate buffer solution with a pH value of 5.5. Stir at a speed of 500 r / min for 10 min, then immerse the polyurethane sponge and let it stand for 30 min. Take it out, drain it, ultrasonically clean it with deionized water for 5 min, and squeeze out the water. The obtained product is denoted as modified polyurethane sponge;

[0058] S3. Immerse the modified polyurethane sponge in a silver nitrate solution with a concentration of 0.1 mol / L and let it stand under ultraviolet light at 365 nm for 30 min. After taking it out and draining, ultrasonically clean it with deionized water for 5 min and squeeze out the water. Place it in an oven at 50 °C and dry it for 6 h. The obtained product is the antibacterial polyurethane sponge intermediate layer.

[0059] The antibacterial and wear-resistant PET non-woven fabric surface layer is prepared from PET chips, silver-loaded carbon nanotube antibacterial agent, and wear-resistant modification components as the main raw materials;

[0060] The preparation steps of the silver-loaded carbon nanotube antibacterial agent are as follows:

[0061] Step 1. Immerse 1 g of multi-walled carbon nanotubes in 40 mL of nitric acid solution with a concentration of 3 mol / L, oxidize and reflux at 60 °C for 30 min. After cooling to room temperature, filter to remove the filtrate and wash with deionized water until neutral. Finally, dry it in an oven at 120 °C for 4 h. The obtained product is denoted as acid-treated multi-walled carbon nanotubes;

[0062] Step 2. Immerse 1 g of acid-treated multi-walled carbon nanotubes in 200 mL of silver nitrate solution with a concentration of 0.2 mol / L, ultrasonically disperse it at a frequency of 30 kHz for 15 min, then add ammonia water solution to adjust the pH value to 6 and let it stand and react for 3 h. Centrifuge at a speed of 6000 r / min for 5 min, wash the precipitate with deionized water 5 times, dry it at 100 °C for 3 h, and then grind it through a 100-mesh sieve. The obtained product is denoted as the silver-loaded carbon nanotube antibacterial agent.

[0063] The preparation method of the wear-resistant modification component is as follows:

[0064] Weigh 5 g of nano-silica and 9 g of polytetrafluoroethylene micro-powder and pour them into a ball mill. Ball mill at a speed of 500 r / min for 5 min, then add 1 g of silane coupling agent KH-550 and 1 g of calcium stearate, and continue to ball mill for 10 min. The obtained product is the wear-resistant modification component.

[0065] The preparation method of the antibacterial and wear-resistant PET non-woven fabric surface layer is as follows:

[0066] Put 100 g of PET chips, 3 g of silver-loaded carbon nanotube antibacterial agent, 3 g of wear-resistant modification component, and 1 g of polyvinylpyrrolidone into a mixer, knead at 270 °C for 5 min, and obtain the antibacterial and wear-resistant PET non-woven fabric surface layer through a meltblown spinning machine. Among them, the temperature of meltblown spinning is 280 °C, the receiving distance of the meltblown cloth is 200 mm, the hot air temperature of hot air traction is 330 °C, the traction air pressure is 0.2 MPa, and the thickness of the antibacterial and wear-resistant PET non-woven fabric surface layer is 0.5 mm.

[0067] A preparation method of a lightweight automotive carpet, and the preparation method is as follows:

[0068] Lay the surface layer of antibacterial and wear-resistant PET non-woven fabric flat on the surface of the intermediate layer of antibacterial polyurethane sponge, and thermally press and form the combination of the two through a thermal pressing process under a pressure of 220 °C. The obtained carpet with upper, middle, and lower layers being the surface layer of antibacterial and wear-resistant PET non-woven fabric, the intermediate layer of antibacterial polyurethane sponge, and the surface layer of antibacterial and wear-resistant PET non-woven fabric is a lightweight automotive carpet.

[0069] Example 2

[0070] A lightweight automotive carpet in this example is composed of the following structure: an intermediate layer of antibacterial polyurethane sponge and a surface layer of antibacterial and wear-resistant PET non-woven fabric;

[0071] The intermediate layer of antibacterial polyurethane sponge is prepared by subjecting polyurethane sponge to antibacterial modification treatment, and its preparation method is as follows:

[0072] S1. Weigh 80 g of polyether polyol and 30 g of polyester polyol and pour them into a flask. Then, successively add 0.4 g of triethylenediamine, 0.2 g of organic zinc catalyst, 1.5 g of foam stabilizer, and 5 g of deionized water. Stir at a speed of 800 r / min for 10 min, then add 50 g of diphenylmethane diisocyanate, and stir at a high speed of 1200 r / min until the mixture turns white. Then pour it into a mold with a thickness of 10 mm and place it in an oven at 50 °C for static foaming for 50 min. The obtained product is denoted as polyurethane sponge;

[0073] S2. Weigh 0.2 g of dopamine hydrochloride and 0.3 g of sodium periodate and add them to 50 mL of sodium acetate buffer solution with a pH value of 5.5. Stir at a speed of 600 r / min for 10 min, then immerse the polyurethane sponge and let it stand for 30 min. Take it out, drain it, ultrasonically clean it with deionized water for 6 min, and squeeze out the water. The obtained product is denoted as modified polyurethane sponge;

[0074] S3. Immerse the modified polyurethane sponge in a silver nitrate solution with a concentration of 0.1 mol / L and let it stand under ultraviolet light at 365 nm for 30 min. Take it out, drain it, ultrasonically clean it with deionized water for 6 min, and squeeze out the water. Place it in an oven at 55 °C and dry it for 6 h. The obtained product is the intermediate layer of antibacterial polyurethane sponge.

[0075] The surface layer of antibacterial and wear-resistant PET non-woven fabric is prepared from PET chips, silver-loaded carbon nanotube antibacterial agent, and wear-resistant modification components as the main raw materials;

[0076] The preparation steps of the silver-loaded carbon nanotube antibacterial agent are as follows:

[0077] Step 1. Immerse 2 g of multi-walled carbon nanotubes in 50 mL of nitric acid solution with a concentration of 3 mol / L, oxidize and reflux at a temperature of 60 °C for 30 min. Cool down to room temperature, filter to remove the filtrate, wash it with deionized water until neutral, and finally dry it in an oven at 120 °C for 4 h. The obtained product is denoted as acid-treated multi-walled carbon nanotubes;

[0078] Step 2: Immerse 2 g of acid-treated multi-walled carbon nanotubes into 200 mL of silver nitrate solution with a concentration of 0.2 mol / L. After ultrasonic dispersion at a frequency of 30 kHz for 20 min, add ammonia water solution to adjust the pH value to 7 and let it stand for reaction for 4 h. After centrifuging at a speed of 6000 r / min for 5 min, rinse the precipitate with deionized water for 6 times, dry it at a temperature of 100 °C for 4 h, and then grind it through a 100-mesh sieve. The obtained product is denoted as silver-loaded carbon nanotube antibacterial agent.

[0079] The preparation method of the wear-resistant modification component is as follows:

[0080] Weigh 8 g of nano-silica and 10 g of polytetrafluoroethylene micropowder and pour them into a ball mill. After ball milling at a speed of 500 r / min for 5 min, add 2 g of silane coupling agent KH-550 and 2 g of calcium stearate, and continue ball milling for 10 min. The obtained product is the wear-resistant modification component.

[0081] The preparation method of the antibacterial and wear-resistant PET non-woven fabric surface layer is as follows:

[0082] Put 100 g of PET chips, 4 g of silver-loaded carbon nanotube antibacterial agent, 5 g of wear-resistant modification component, and 2 g of polyvinylpyrrolidone into a mixer. Knead at a temperature of 290 °C for 10 min, and then obtain the antibacterial and wear-resistant PET non-woven fabric surface layer through a meltblown spinning machine. Among them, the temperature of meltblown spinning is 300 °C, the receiving distance of the meltblown cloth is 200 mm, the hot air temperature of hot air traction is 350 °C, the traction air pressure is 0.3 MPa, and the thickness of the antibacterial and wear-resistant PET non-woven fabric surface layer is 0.8 mm.

[0083] A preparation method of a lightweight automotive carpet, and the preparation method is as follows:

[0084] Lay the antibacterial and wear-resistant PET non-woven fabric surface layer flat on the surface of the antibacterial polyurethane sponge intermediate layer, and thermally press and form and combine the two through a hot pressing process under a pressure of 230 °C. The obtained carpet with upper, middle, and lower layers being the antibacterial and wear-resistant PET non-woven fabric surface layer, the antibacterial polyurethane sponge intermediate layer, and the antibacterial and wear-resistant PET non-woven fabric surface layer is the lightweight automotive carpet.

[0085] Example 3

[0086] A lightweight automotive carpet in this example, and the lightweight automotive carpet is composed of the following structures: an antibacterial polyurethane sponge intermediate layer and an antibacterial and wear-resistant PET non-woven fabric surface layer;

[0087] The antibacterial polyurethane sponge intermediate layer is obtained by subjecting polyurethane sponge to antibacterial modification treatment, and its preparation method is as follows:

[0088] S1. Weigh 75 g of polyether polyol and 25 g of polyester polyol and pour them into a flask. Then, successively add 0.4 g of triethylenediamine, 0.2 g of organic zinc catalyst, 1.3 g of foam stabilizer, and 4 g of deionized water. Stir at a speed of 700 r / min for 10 min, then add 49 g of diphenylmethane diisocyanate. Stir at a high speed of 1100 r / min until the mixture turns white, then pour it into a mold with a thickness of 8 mm and place it in an oven at 50 °C for static foaming for 40 min. The obtained product is denoted as polyurethane sponge;

[0089] S2. Weigh 0.2 g of dopamine hydrochloride and 0.3 g of sodium periodate and add them to 50 mL of sodium acetate buffer solution with a pH value of 5.5. Stir at a speed of 600 r / min for 10 min, then immerse the polyurethane sponge and let it stand for 30 min. Take it out, drain, ultrasonically clean with deionized water for 5 min, and squeeze out the water. The obtained product is denoted as modified polyurethane sponge;

[0090] S3. Immerse the modified polyurethane sponge in a silver nitrate solution with a concentration of 0.1 mol / L and let it stand under ultraviolet light at 365 nm for 30 min. Take it out, drain, ultrasonically clean with deionized water for 6 min, and squeeze out the water. Place it in an oven at 53 °C and dry for 6 h. The obtained product is the intermediate layer of antibacterial polyurethane sponge.

[0091] The antibacterial and wear-resistant PET non-woven fabric surface layer is prepared from PET chips, silver-loaded carbon nanotube antibacterial agent, and wear-resistant modification components as the main raw materials;

[0092] The preparation steps of the silver-loaded carbon nanotube antibacterial agent are as follows:

[0093] Step 1. Immerse 2 g of multi-walled carbon nanotubes in 45 mL of nitric acid solution with a concentration of 3 mol / L, oxidize and reflux at 60 °C for 30 min. Cool to room temperature, filter to remove the filtrate, wash with deionized water until neutral, and finally dry in an oven at 120 °C for 4 h. The obtained product is denoted as acid-treated multi-walled carbon nanotubes;

[0094] Step 2. Immerse 2 g of acid-treated multi-walled carbon nanotubes in 200 mL of silver nitrate solution with a concentration of 0.2 mol / L, ultrasonically disperse at a frequency of 30 kHz for 18 min, then add ammonia water solution to adjust the pH value to 7 and let it stand for reaction for 4 h. Centrifuge at a speed of 6000 r / min for 5 min, wash the precipitate with deionized water 6 times, dry at 100 °C for 4 h, and then grind through a 100-mesh sieve. The obtained product is denoted as silver-loaded carbon nanotube antibacterial agent.

[0095] The preparation method of the wear-resistant modification component is as follows:

[0096] Weigh 7 g of nano-silica and 10 g of polytetrafluoroethylene micropowder and pour them into a ball mill. After ball milling at a speed of 500 r / min for 5 min, add 2 g of silane coupling agent KH-550 and 2 g of calcium stearate, and continue ball milling for 10 min. The obtained product is the wear-resistant modification component.

[0097] The preparation method of the surface layer of antibacterial and wear-resistant PET non-woven fabric is as follows:

[0098] Put 100 g of PET chips, 4 g of silver-loaded carbon nanotube antibacterial agent, 4 g of wear-resistant modification component and 2 g of polyvinylpyrrolidone into an internal mixer, and carry out internal mixing at a temperature of 280 °C for 8 min. Then, the surface layer of antibacterial and wear-resistant PET non-woven fabric is obtained through a meltblown spinning machine. Among them, the temperature of meltblown spinning is 290 °C, the receiving distance of the meltblown cloth is 200 mm, the hot air temperature of hot air traction is 340 °C, the traction air pressure is 0.3 MPa, and the thickness of the surface layer of antibacterial and wear-resistant PET non-woven fabric is 0.7 mm.

[0099] A preparation method of a lightweight automotive carpet is as follows:

[0100] Lay the surface layer of antibacterial and wear-resistant PET non-woven fabric flat on the surface of the antibacterial polyurethane sponge intermediate layer, and carry out hot pressing and molding combination on the two through a hot pressing process under a pressure of 225 °C. The obtained carpet with upper, middle and lower layers being the surface layer of antibacterial and wear-resistant PET non-woven fabric, the antibacterial polyurethane sponge intermediate layer and the surface layer of antibacterial and wear-resistant PET non-woven fabric respectively is the lightweight automotive carpet.

[0101] Comparative Example 1

[0102] A lightweight automotive carpet and its preparation method provided in this comparative example are generally the same as those in Example 1. The main difference is that in this Comparative Example 1, the antibacterial polyurethane sponge intermediate layer in Example 1 is replaced with the polyurethane sponge in Example 1.

[0103] Comparative Example 2

[0104] A lightweight automotive carpet and its preparation method provided in this comparative example are generally the same as those in Example 1. The main difference is that in this Comparative Example 2, the silver-loaded carbon nanotube antibacterial agent in Example 1 is replaced with unmodified multi-walled carbon nanotubes.

[0105] Comparative Example 3

[0106] A lightweight automotive carpet and its preparation method provided in this comparative example are generally the same as those in Example 1. The main difference is that in this Comparative Example 3, the wear-resistant modification component in Example 1 is replaced with nano-silica.

[0107] Comparative Example 4

[0108] A lightweight automotive carpet provided in this comparative example and its preparation method are generally the same as those in Example 1, and the main difference lies in that: in this Comparative Example 4, the wear-resistant modification component in Example 1 is replaced with polytetrafluoroethylene micropowder.

[0109] Performance Test

[0110] The lightweight automotive carpets prepared in Examples 1-3 and Comparative Examples 1-4 are respectively marked as Example 1, Example 2, Example 3, Comparative Example 1, Comparative Example 2, Comparative Example 3, and Comparative Example 4, and then the performances of Examples 1-3 and Comparative Examples 1-4 are detected. The specific detection methods and detection items are as follows:

[0111] 1. Referring to the standard of GB / T21196.2-2007, the wear resistance of Examples 1-3 and Comparative Examples 1-4 is tested. The load during the test is 1600 g, and the data of the total number of wear resistance times obtained are recorded in the following table;

[0112] 2. Referring to the standard of GB / T20944.3-2008, the antibacterial performance of Examples 1-3 and Comparative Examples 1-4 is tested. The detected bacteria are Escherichia coli, Staphylococcus aureus, and Aspergillus, and the data of the antibacterial rate obtained are recorded in the following table;

[0113]

[0114] It can be seen from the data in the above table that the wear resistance of the lightweight automotive carpets in Examples 1-3 of the present invention is significantly better than that of Comparative Examples 3-4, indicating that adding a wear-resistant modification component in the preparation of lightweight automotive carpets can significantly improve the wear resistance of the carpets. While adding a single and unmodified nano-silica or polytetrafluoroethylene micropowder has a poor effect on improving the wear resistance. Secondly, the antibacterial performance of the lightweight automotive carpets in Examples 1-3 of the present invention is significantly better than that of Comparative Examples 1-2, indicating that adding the antibacterial polyurethane sponge intermediate layer and silver-loaded carbon nanotube antibacterial agent in the preparation of lightweight automotive carpets can significantly improve the antibacterial performance; Therefore, the lightweight automotive carpet prepared in the present invention has better application prospects.

[0115] It should be noted that in this document, relational terms such as first and second are only used to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any actual relationship or order between these entities or operations. Moreover, the terms "include", "comprise" or any other variant thereof are intended to cover non-exclusive inclusion, such that a process, method, article or device comprising a series of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article or device. Without further limitation, an element defined by the phrase "comprising an..." does not exclude the presence of additional identical elements in the process, method, article or device comprising said element.

[0116] The above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit it; although the present invention has been described in detail with reference to the foregoing embodiments, those of ordinary skill in the art should understand that they can still modify the technical solutions recorded in the foregoing embodiments, or perform equivalent replacements for some of the technical features; and these modifications or replacements will not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A lightweight automotive carpet, characterized in that, The lightweight automotive carpet consists of the following structure: an antibacterial polyurethane sponge intermediate layer and an antibacterial and wear-resistant PET non-woven fabric surface layer; The antibacterial polyurethane sponge intermediate layer is prepared by subjecting polyurethane sponge to antibacterial modification treatment; The antibacterial and wear-resistant PET non-woven fabric surface layer is prepared from PET chips, silver-loaded carbon nanotube antibacterial agent and wear-resistant modification components as the main raw materials.

2. The lightweight automotive carpet according to claim 1, wherein, The preparation method of the antibacterial polyurethane sponge intermediate layer is as follows: S1. Weigh 70 - 80 g of polyether polyol and 20 - 30 g of polyester polyol and pour them into a flask. Then, successively add 0.3 - 0.4 g of triethylenediamine, 0.1 - 0.2 g of organic zinc catalyst, 1.2 - 1.5 g of foam stabilizer and 3 - 5 g of deionized water. After quickly stirring evenly, add 48 - 50 g of diphenylmethane diisocyanate. Stir at a high speed until the mixture turns white, then pour it into a mold and place it in an oven at 50 °C for static foaming for 30 - 50 min. The obtained product is denoted as polyurethane sponge; S2. Weigh 0.1 - 0.2 g of dopamine hydrochloride and 0.2 - 0.3 g of sodium periodate and add them to 50 mL of sodium acetate buffer solution. After stirring and dispersing, immerse the polyurethane sponge and let it stand for 30 min. Take it out, drain it, ultrasonically clean it with deionized water for 5 - 6 min and squeeze out the water. The obtained product is denoted as modified polyurethane sponge; S3. Immerse the modified polyurethane sponge in silver nitrate solution and let it stand under ultraviolet light at 365 nm for 30 min. Take it out, drain it, ultrasonically clean it with deionized water for 5 - 6 min and squeeze out the water. After drying treatment, the obtained product is the antibacterial polyurethane sponge intermediate layer.

3. The lightweight automotive carpet according to claim 2, wherein, The method of quickly stirring evenly in S1 is to stir at a speed of 600 - 800 r / min for 10 min. The rotation speed of high-speed stirring in S1 is 1000 - 1200 r / min, and the thickness of the polyurethane sponge in S1 is 5 - 10 mm.

4. The lightweight automotive carpet according to claim 2, characterized in that, The pH value of the sodium acetate buffer solution in S2 is 5.

5. The method of stirring and dispersing in S2 is to stir at a speed of 500 - 600 r / min for 10 min. The concentration of the silver nitrate solution in S3 is 0.1 mol / L, and the method of drying treatment in S3 is to dry it in an oven at 50 - 55 °C for 6 h.

5. A lightweight automotive carpet according to claim 1, wherein, The preparation steps of the silver-loaded carbon nanotube antibacterial agent are as follows: Step 1. Immerse 1 - 2 g of multi-walled carbon nanotubes in 40 - 50 mL of nitric acid solution, oxidize and reflux at 60 °C for 30 min. After cooling to room temperature, filter to remove the filtrate and wash it with deionized water until neutral. Finally, dry it in an oven at 120 °C for 4 h. The obtained product is denoted as acid-treated multi-walled carbon nanotubes; Step 2. Immerse 1 - 2 g of acid-treated multi-walled carbon nanotubes in 200 mL of silver nitrate solution with a concentration of 0.2 mol / L. After ultrasonic dispersion, adjust the pH value to 6 - 7 and let it stand for reaction for 3 - 4 h. After centrifugation, wash the precipitate with deionized water 5 - 6 times, dry it at 100 °C for 3 - 4 h and then grind it through a 100-mesh sieve. The obtained product is denoted as silver-loaded carbon nanotube antibacterial agent.

6. The lightweight automotive carpet according to claim 5, characterized in that, The concentration of the nitric acid solution in Step 1 is 3 mol / L. The method of ultrasonic dispersion in Step 2 is to perform ultrasonic dispersion at a frequency of 30 kHz for 15 - 20 min. In Step 2, an ammonia water solution is added dropwise to adjust the pH value. The method of centrifugation in Step 2 is to centrifuge at a speed of 6000 r / min for 5 min.

7. A lightweight automotive carpet according to claim 1, characterized in that The preparation method of the wear-resistant modification component is as follows: Weigh 5 - 8 g of nano-silica and 9 - 10 g of polytetrafluoroethylene micropowder and pour them into a ball mill. After ball milling at a speed of 500 r / min for 5 min, add 1 - 2 g of silane coupling agent KH-550 and 1 - 2 g of calcium stearate, and continue ball milling for 10 min. What is obtained is the wear-resistant modification component.

8. A lightweight automotive carpet according to claim 1, characterized in that, The preparation method of the antibacterial and wear-resistant PET non-woven fabric surface layer is as follows: Pour 100 g of PET chips, 3 - 4 g of silver-loaded carbon nanotube antibacterial agent, 3 - 5 g of wear-resistant modification component, and 1 - 2 g of polyvinylpyrrolidone into an internal mixer, and carry out internal mixing at a temperature of 270 - 290 °C for 5 - 10 min, and then obtain the antibacterial and wear-resistant PET non-woven fabric surface layer through a meltblown spinning machine.

9. A lightweight automotive carpet according to claim 1, wherein, In the preparation method of the antibacterial and wear-resistant PET non-woven fabric surface layer, the meltblowing temperature is 280 - 300 °C, the receiving distance of the meltblown cloth is 200 mm, the hot air temperature of the hot air traction is 330 - 350 °C, the traction air pressure is 0.2 - 0.3 MPa, and the thickness of the antibacterial and wear-resistant PET non-woven fabric surface layer is 0.5 - 0.8 mm.

10. The preparation method of a lightweight automotive carpet according to any one of claims 1-9, characterized in that, The preparation method is as follows: Lay the antibacterial and wear-resistant PET non-woven fabric surface layer flat on the surface of the antibacterial polyurethane sponge intermediate layer, and perform hot pressing and molding combination on the two through a hot pressing process under a pressure of 220 - 230 °C. The obtained carpet with upper, middle, and lower layers being the antibacterial and wear-resistant PET non-woven fabric surface layer, the antibacterial polyurethane sponge intermediate layer, and the antibacterial and wear-resistant PET non-woven fabric surface layer respectively is the lightweight automotive carpet.

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