Water-resistant and stain-resistant automotive carpet and preparation method thereof

Abstract

The invention discloses a water-resistant and stain-resistant automotive carpet and a preparation method thereof.The preparation method of the water-resistant and stain-resistant automotive carpet comprises the steps that S1, a base layer is prepared; s2, preparing a waterproof layer; s3, preparing a functional layer; s4, preparing a surface layer; and S5, heat setting treatment. According to the water-resistant and stain-resistant automobile carpet and the preparation method thereof, by optimizing the structure, material composition and monitoring mode of the carpet, the water-resistant and stain-resistant performance of the carpet is remarkably improved, meanwhile, the good softness and breathability of the carpet are kept, and the humidity and pollutants of the carpet can be monitored in real time.

Description

Technical Field

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

[0002] As an important part of automotive interiors, automotive carpets can not only create a comfortable driving environment inside the vehicle, but also play a role in sound insulation and heat insulation. However, existing automotive carpets generally have poor water- and stain-resistant performance. In daily use, pollutants such as rainwater, beverages, and dust can easily penetrate into the carpet interior, which is not only difficult to clean, breeds bacteria, affects the air quality inside the vehicle, but also may cause the carpet to mildew and rot due to long-term moisture, thereby damaging the vehicle chassis and shortening the service life of the carpet.

[0003] Therefore, developing an automotive carpet that can effectively improve water- and stain-resistant performance while taking into account comfort and economy has become an urgent problem to be solved in the field of automotive interiors. Summary of the Invention

[0004] The main object of the present invention is to provide a water- and stain-resistant automotive carpet and a preparation method thereof. By optimizing the structure, material composition, and monitoring method of the carpet, the water- and stain-resistant performance of the carpet is significantly improved, while maintaining its good softness and breathability, and being able to monitor the humidity and pollutants of the carpet in real time.

[0005] To achieve the above object, the present invention provides a preparation method for a water- and stain-resistant automotive carpet, comprising the following steps:

[0006] Step S1: Prepare the base layer. Melt-spin polypropylene chips into PP fibers, and then form a PP fiber felt through needling or hydroentangling processes, controlling the thickness of the PP fiber felt to be 5 - 8 mm;

[0007] Step S2: Prepare the water-resistant layer. Adopt a hot-pressing composite process to composite a TPU (thermoplastic polyurethane) film with the PP fiber felt, controlling the hot-pressing temperature at 120 - 150 °C, the pressure at 0.5 - 1.0 MPa, and the composite time at 3 - 5 min, thereby forming a water-resistant layer on the base layer (the TPU film has excellent water resistance, flexibility, and chemical corrosion resistance, and can effectively prevent moisture and stains from penetrating into the carpet interior);

[0008] Step S3: Prepare the functional layer. Immerse the polyester fiber (PET) in a mixed solution containing nano-TiO₂ particles and silicone compounds. The concentration of TiO₂ particles is 0.5 - 1.0 wt%, the concentration of silicone compounds is 1.0 - 2.0 wt%, and the immersion time is 10 - 15 min. Then dry it at 80 - 100 °C to form the functional layer. Attach the functional layer to the surface of the TPU film through needling or hydroentangling process, and control the thickness of the functional layer to be 2 - 3 mm. (In the functional layer, TiO₂ particles have photocatalytic self-cleaning function and can decompose organic pollutants under light; silicone compounds endow the fiber surface with low surface energy, making it difficult for stains to adhere, thus significantly improving the stain resistance of the carpet).

[0009] Step S4: Prepare the surface layer. Lay nylon fibers on the surface of the functional layer through tufting process to form the surface layer of the carpet, and control the thickness of the surface layer to be 3 - 5 mm.

[0010] Step S5: Heat setting treatment. Control the temperature at 130 - 160 °C and the time at 5 - 10 min to stabilize the structure and size of the carpet.

[0011] To achieve the above objectives, the present invention also provides a water and stain resistant automotive carpet, which includes a surface layer, a functional layer, a water resistant layer and a base layer from top to bottom, wherein:

[0012] Embed humidity sensors at preset positions of the water resistant layer (such as the front foot area, under the rear seats, etc.). The humidity sensors continuously monitor the humidity change of the environment where the carpet is located, and transmit the obtained humidity data to the vehicle control system through the first wireless transmission unit, so that the control system analyzes the humidity data. If it is determined that the humidity of the carpet continuously exceeds the preset normal level, indicating that the carpet is damp, the vehicle control system will trigger a dehumidification reminder at this time;

[0013] Embed pollution monitoring sensors at preset positions of the functional layer (such as the foot positions in each area) (including optical sensors or electrochemical sensors. The optical sensors judge the type and coverage area of stains by analyzing the intensity and spectral characteristics of the reflected light; the electrochemical sensors can perform quantitative detection on specific chemical substances, such as sugars and oils in beverages, etc.). The pollution monitoring sensors continuously monitor the pollutant data of the carpet including stains and dust, and transmit the obtained pollutant data to the vehicle control system through the second wireless transmission unit, so that the control system analyzes the pollutant data. When the pollutant content of the carpet exceeds the preset threshold, the vehicle control system triggers a cleaning reminder.

[0014] As a further preferred technical solution of the above technical solution, for the dehumidification reminder, the vehicle's display screen pops up a dehumidification reminder message, emits an alarm sound corresponding to dehumidification, and pushes a dehumidification reminder message to the owner's mobile phone, so as to inform the owner that the carpet needs dehumidification.

[0015] As a further preferred technical solution of the above technical solution, for the cleaning reminder, the vehicle's display screen pops up a cleaning reminder message, emits an alarm sound corresponding to cleaning, and pushes a cleaning reminder message to the owner's mobile phone, so as to inform the owner that the carpet needs cleaning.

[0016] As a further preferred technical solution of the above technical solution, after the vehicle control system triggers the dehumidification reminder, it is linked with the vehicle's air conditioning system to automatically turn on the dehumidification mode.

[0017] As a further preferred technical solution of the above technical solution, after the vehicle control system triggers the cleaning reminder, it is linked with the vehicle's air conditioning system to automatically turn on the ventilation and odor removal mode. Description of the Drawings

[0018] Figure 1 is a schematic flow chart of the present invention. Detailed Embodiments

[0019] The following description is used to disclose the present invention so that those skilled in the art can implement the present invention. The preferred embodiments described below are only examples, and those skilled in the art can think of other obvious variations. The basic principles defined in the following description of the present invention can be applied to other embodiments, variations, improvements, equivalent embodiments, and other technical solutions that do not depart from the spirit and scope of the present invention.

[0020] In the preferred embodiment of the present invention, those skilled in the art should note that the automobiles, vehicles, etc. involved in the present invention can be regarded as prior art.

[0021] Preferred Embodiment.

[0022] As Figure 1 shown, the present invention discloses a preparation method of a water-resistant and stain-resistant automotive carpet, including the following steps:

[0023] Step S1: Prepare the base layer. Melt-spin the polypropylene chips into PP fibers, and then form a PP fiber felt through a needling or hydroentangling process, controlling the thickness of the PP fiber felt to be 5-8 mm;

[0024] Step S2: Prepare the water-resistant layer. Adopt the hot-pressing composite process to composite the TPU (thermoplastic polyurethane) film with the PP fiber felt. The hot-pressing temperature is controlled at 120 - 150 °C, the pressure is 0.5 - 1.0 MPa, and the composite time is 3 - 5 min, so as to form a water-resistant layer on the base layer (the TPU film has excellent water resistance, flexibility and chemical corrosion resistance, and can effectively prevent moisture and stains from penetrating into the carpet interior);

[0025] Step S3: Prepare the functional layer. Immerse the polyester fiber (PET) in a mixed solution containing nano-TiO2 particles and silicone compounds. The concentration of TiO2 particles is 0.5 - 1.0 wt%, the concentration of silicone compounds is 1.0 - 2.0 wt%, the immersion time is 10 - 15 min, and then dry it at 80 - 100 °C to form the functional layer. Attach the functional layer to the surface of the TPU film by needling or hydroentangling process, and control the thickness of the functional layer to be 2 - 3 mm (in the functional layer, the TiO2 particles have photocatalytic self-cleaning function and can decompose organic pollutants under light; the silicone compounds endow the fiber surface with low surface energy, making it difficult for stains to adhere, thus significantly improving the stain resistance of the carpet);

[0026] Step S4: Prepare the surface layer. Lay the nylon fiber on the surface of the functional layer by tufting process to form the surface layer of the carpet, and control the thickness of the surface layer to be 3 - 5 mm (the surface layer is made of soft nylon (PA) fiber, providing a comfortable touch for the driver and passengers. At the same time, the nylon fiber has good wear resistance and antistatic performance);

[0027] Step S5: Heat setting treatment. The temperature is controlled at 130 - 160 °C, and the time is 5 - 10 min to stabilize the structure and size of the carpet.

[0028] The present invention also discloses a water-resistant and stain-resistant automotive carpet, which includes a surface layer, a functional layer, a water-resistant layer and a base layer from top to bottom, wherein:

[0029] Embed a humidity sensor at a preset position of the water-resistant layer (such as the front row foot area, under the rear row seats, etc.). The humidity sensor monitors the humidity change of the environment where the carpet is located in real time, and transmits the obtained humidity data to the vehicle control system through the first wireless transmission unit, so that the control system analyzes the humidity data. If it is judged that the humidity of the carpet continues to be higher than the preset normal level, it indicates that the carpet is damp. At this time, the vehicle control system triggers a dehumidification reminder;

[0030] A pollution monitoring sensor (including an optical sensor or an electrochemical sensor) is embedded at a preset position of the functional layer (such as the foot position in each area). The optical sensor judges the type and coverage area of the stain by analyzing the intensity and spectral characteristics of the reflected light, while the electrochemical sensor can conduct quantitative detection for specific chemical substances, such as sugars and oils in beverages. The pollution monitoring sensor monitors the pollutant data of the carpet in real time, including stains and dust, and transmits the obtained pollutant data to the vehicle control system through the second wireless transmission unit, so that the control system analyzes the pollutant data. When the pollutant content of the carpet exceeds the preset threshold, the vehicle control system triggers a cleaning reminder.

[0031] Specifically, for the dehumidification reminder, a dehumidification reminder message pops up on the vehicle's display screen, and an alarm sound corresponding to dehumidification is emitted, and a dehumidification reminder message is pushed to the owner's mobile phone, so as to inform the owner that the carpet needs dehumidification.

[0032] More specifically, for the cleaning reminder, a cleaning reminder message pops up on the vehicle's display screen, and an alarm sound corresponding to cleaning is emitted, and a cleaning reminder message is pushed to the owner's mobile phone, so as to inform the owner that the carpet needs cleaning.

[0033] Furthermore, after the vehicle control system triggers the dehumidification reminder, it is linked with the vehicle's air conditioning system to automatically turn on the dehumidification mode.

[0034] Even further, after the vehicle control system triggers the cleaning reminder, it is linked with the vehicle's air conditioning system to automatically turn on the ventilation and odor removal mode.

[0035] It is worth mentioning that the technical features of the automobile, vehicle, etc. involved in this invention patent application should be regarded as the prior art. The specific structures, working principles, control methods, and spatial layout methods that may be involved can be selected conventionally in this field, and should not be regarded as the invention points of this invention patent. This invention patent will not be further specifically elaborated.

[0036] For those skilled in the art, it is still possible to modify the technical solutions described in the foregoing embodiments, or perform equivalent replacements for some of the technical features. Any modifications, equivalent replacements, improvements, etc. made within the spirit and principle of the present invention shall be included within the protection scope of the present invention.

Claims

1. A preparation method of a water- and stain-resistant automotive carpet, characterized in that, It includes the following steps: Step S1: Prepare the base layer. The polypropylene chips are made into PP fibers through a melt spinning process, and then a PP fiber felt is formed through a needling or hydroentangling process, controlling the thickness of the PP fiber felt to be 5 - 8 mm; Step S2: Prepare the water - resistant layer. Using a hot - pressing composite process, the TPU film is compounded with the PP fiber felt. The hot - pressing temperature is controlled at 120 - 150 °C, the pressure is 0.5 - 1.0 MPa, and the composite time is 3 - 5 min, thereby forming a water - resistant layer on the base layer; Step S3: Prepare the functional layer. The polyester fiber is impregnated in a mixed solution containing nano - TiO₂ particles and silicone compounds. The concentration of TiO₂ particles is 0.5 - 1.0 wt%, the concentration of silicone compounds is 1.0 - 2.0 wt%, the impregnation time is 10 - 15 min, and then it is dried at 80 - 100 °C to form the functional layer. The functional layer is attached to the surface of the TPU film through a needling or hydroentangling process, controlling the thickness of the functional layer to be 2 - 3 mm; Step S4: Prepare the surface layer. The nylon fiber is laid on the surface of the functional layer through a tufting process to form the surface layer of the carpet, controlling the thickness of the surface layer to be 3 - 5 mm; Step S5: Heat - setting treatment. The temperature is controlled at 130 - 160 °C, and the time is 5 - 10 min to stabilize the structure and size of the carpet.

2. A water-resistant and stain-resistant automotive carpet, which is applied to the preparation method of a water-resistant and stain-resistant automotive carpet described in claim 1, and is characterized in that, From top to bottom, it includes a surface layer, a functional layer, a water - resistant layer, and a base layer, where: A humidity sensor is embedded at a preset position in the water - resistant layer. The humidity sensor monitors the humidity change of the environment where the carpet is located in real - time, and transmits the obtained humidity data to the vehicle's control system through the first wireless transmission unit, so that the control system analyzes the humidity data. If it is determined that the humidity of the carpet continuously exceeds the preset normal level, indicating that the carpet is damp, at this time, the vehicle's control system triggers a dehumidification reminder; A pollution monitoring sensor is embedded at a preset position in the functional layer. The pollution monitoring sensor monitors the pollutant data of the carpet including stains and dust in real - time, and transmits the obtained pollutant data to the vehicle's control system through the second wireless transmission unit, so that the control system analyzes the pollutant data. When the pollutant content of the carpet exceeds the preset threshold, the vehicle control system triggers a cleaning reminder.

3. The water-resistant and stain-resistant automotive carpet according to claim 2, characterized in that, For the dehumidification reminder, a dehumidification reminder message pops up on the vehicle's display screen, and an alarm sound corresponding to dehumidification is emitted, and a dehumidification reminder message is pushed to the owner's mobile phone, thereby informing the owner that the carpet needs dehumidification.

4. A water- and stain-resistant automotive carpet according to claim 3, wherein For the cleaning reminder, a cleaning reminder message pops up on the vehicle's display screen, and an alarm sound corresponding to cleaning is emitted, and a cleaning reminder message is pushed to the owner's mobile phone, thereby informing the owner that the carpet needs cleaning.

5. The water-resistant and stain-resistant automotive carpet according to claim 4, characterized in that, After the vehicle control system triggers the dehumidification reminder, it is linked with the vehicle's air - conditioning system to automatically turn on the dehumidification mode.

6. The water-resistant and stain-resistant automotive carpet according to claim 5, wherein, After the vehicle control system triggers the cleaning reminder, it is linked with the vehicle's air - conditioning system to automatically turn on the ventilation and odor - removal mode.

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