A tufted carpet composited with polymer coconut shell charcoal and its preparation method and application

Abstract

The present invention provides a tufted carpet of composite polymer coconut shell charcoal, and its preparation method and application, belonging to the field of polymer composite carpets. The present invention realizes the efficient removal of organic matter and toxic and harmful substances in the carpet by means of a composite adsorption layer on the back of the adhesive layer. The coconut shell charcoal in the adsorption layer is acidified with nitric acid to introduce active functional groups, which are hydrothermally reacted with the titanium source, and then calcined to enhance the crystallinity and interfacial bonding strength, thereby realizing the dynamic cycle of "adsorption-photocatalytic decomposition" of volatile organic compounds. At the same time, the needling process is combined to enhance the interlayer bonding, and simultaneously achieve high mechanical strength and environmental performance. Through multi-component synergy and process optimization, the present invention provides a carpet solution with both functionality and durability for fields such as automotive interiors.

Description

Technical Field

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

[0002] With the gradual development of new energy vehicles, environmental requirements for vehicles are also increasing. This extends beyond vehicle exhaust emission standards to encompass the environmental friendliness of related auto parts. Among auto parts, seat covers and carpets are the primary sources of odor within vehicle interiors. Due to the relatively small interior space and limited ventilation systems, air circulation is inefficient, making it difficult to effectively expel harmful gases from carpets. Volatile organic compounds (VOCs) such as benzene, aldehydes, and alkanes are the most common in automotive carpets. Formaldehyde and benzene are the most hazardous to humans and are also the most difficult to remove. As summer temperatures rise, these organic compounds are continuously released, posing a serious health threat to drivers and passengers. Long-term exposure can lead to respiratory illnesses, neurological damage, and other problems.

[0003] To address this issue, existing automotive carpets often incorporate an adsorption layer during the carpet manufacturing process to absorb volatile organic compounds (VOCs), or employ environmentally friendly adhesives with fewer organic compounds. For example, patent CN201736863U discloses an automotive carpet with an adsorption layer made of bamboo charcoal fiber on the upper surface of the carpet body. Below the adsorption layer is a shaping layer, and below that is a sound insulation layer.

[0004] CN109627418A discloses a method for preparing a highly sound-absorbing polyurethane automotive carpet. The highly sound-absorbing polyurethane automotive carpet comprises material A and material B, wherein material A comprises polyester polyol, polyether polyol, a tertiary amine catalyst, hydroxy silicone oil, a chain extender, and a foaming agent; and material B comprises liquefied MDI, crude MDI, and pure 2.4'-MDI.

[0005] While the adsorption layer described above can absorb some organic matter, the small surface area of ​​the adsorption layer limits the amount of organic matter it can absorb. Furthermore, the layer adsorbs or decomposes released pollutants, failing to suppress TVOC release at the source. Furthermore, the addition of a partial adsorption layer can affect carpet strength and other properties, while the cost of using "formaldehyde-free" glue is significantly higher than that of traditional latex. This leads to significant limitations in traditional technologies for improving in-car air quality within the industry.

[0006] In summary, car carpets are the main source of odor in cars, and they contain high levels of volatile organic compounds. There are urgent problems to be solved in methods for removing volatile organic compounds, such as high cost, limited removal volume, and adverse effects on carpet strength. Summary of the Invention

[0007] To address the above problems, the present invention provides a tufted carpet composited with polymer coconut shell charcoal, a preparation method, and an application thereof. By preparing a specific adsorption material and compounding it into the tufted carpet, the adsorption material can continuously absorb organic matter in the tufted carpet, effectively reducing the release of organic matter in the carpet and weakening the unpleasant odor when the carpet is used.

[0008] The present invention provides a tufted carpet of composite polymer coconut shell charcoal. The tufted carpet of composite polymer coconut shell charcoal has a multi-layer structure, which comprises, from bottom to top, a base layer, a reinforcement layer, an adsorption layer, an adhesive layer, a base fabric layer, and a pile layer. The raw materials in the adsorption layer include polyethylene powder, formaldehyde-removing crystals, a compatibilizer, and coconut shell charcoal. The formaldehyde-removing crystals are loaded on the coconut shell charcoal, and then mixed with the compatibilizer and polyethylene powder and then sprinkled on the adhesive layer. The adsorption layer is prepared at high temperature.

[0009] The thickness of the composite polymer coconut shell charcoal tufted carpet is 12.4-12.9 mm, and the weight is 1910-1997 g / m 2 , the number of cut pile loops is 2550-2660 / 100cm 2 , the pile height is 4-5mm, and the tuft extraction force is 26-30N;

[0010] The tufted carpet of the composite polymer coconut shell charcoal has a peeling force of 58-66N, a weft breaking strength of 1340-1410N / 5cm, a warp breaking strength of 1520-1630N / 5cm, a weft tearing strength of 210-270N, and a warp tearing strength of 210-280N.

[0011] The odor level of the composite polymer coconut shell charcoal tufted carpet is 3.5-5, the content of toxic and harmful substances is ≤1000mg / kg, the content of cadmium is ≤100mg / kg, and the content of polycyclic aromatic hydrocarbons is ≤0.2mg / kg;

[0012] The formaldehyde content in the volatile organic matter content of the tufted carpet of the composite high molecular coconut shell charcoal is less than 19 μg / m 3 , acetaldehyde content <48.5μg / m 3 , toluene content <5.2μg / m 3 , while acrylic acid, acetone, benzene, ethylbenzene, xylene (o-m-p), and styrene were not detected; the total volatile organic compound (TVOC) content was <1170μg / m 3 .

[0013] Furthermore, the tufted carpet made of composite polymer coconut shell charcoal has no cracks, breaks or delamination after a low-temperature impact test.

[0014] The present invention also provides a method for preparing the composite polymer coconut shell charcoal tufted carpet, comprising the following steps:

[0015] Step 1: Tufting bulked continuous filament yarn (BCF yarn) onto a non-woven base fabric through a tufting machine to obtain a pile layer and a base fabric layer; and coating the bottom of the base fabric layer with water-based foamed latex, and drying the mixture to obtain an adhesive layer;

[0016] Step 2, adding concentrated nitric acid to the coconut shell charcoal under low temperature stirring, gradually heating and stirring to acidify, washing the acidified coconut shell charcoal with deionized water, and drying after washing to obtain activated coconut shell charcoal;

[0017] Step 3, stirring and dispersing the activated coconut shell charcoal and the formaldehyde-removing crystals in anhydrous ethanol and deionized water, reacting them in a closed hydrothermal manner after ultrasonication, cooling and filtering, and drying the solid product to obtain in-situ grown coconut shell charcoal;

[0018] Step 4, calcining the in-situ grown coconut shell charcoal and then cooling it to room temperature to obtain loaded coconut shell charcoal, and uniformly mixing the loaded coconut shell charcoal with a compatibilizer and polyethylene powder to obtain organic coconut shell charcoal;

[0019] Step 5: Evenly sprinkle the organic coconut shell charcoal on the back of the adhesive layer, heat it to melt and bond it to the back of the adhesive layer, and cool it to room temperature to obtain an adsorption layer. Then, laminate a polyethylene-polyamide-polyethylene composite film (PEPAPE film) on the back of the adsorption layer, and cool it to room temperature to obtain a reinforcement layer. Laminate a polyethylene terephthalate (PET) needle-punched felt bottom layer on the back of the reinforcement layer to obtain the composite polymer coconut shell charcoal tufted carpet.

[0020] Furthermore, the gram weight of the bulked continuous filament in step 1 is 350-500 gsm.

[0021] Furthermore, the non-woven fabric in step 1 has a gram weight of 100-120 gsm.

[0022] Furthermore, the non-woven fabric in step 1 is a polyethylene terephthalate non-woven fabric.

[0023] Furthermore, the needle pitch of the tufting machine in step 1 is 50.39 needles / 10 cm, the row spacing is 50-55 needles / 10 cm, the needling depth is 5-6 mm, and the needle frequency is 1000-1300 RPM.

[0024] Furthermore, the water-based foamed latex in step 1 has a gram weight of 180-200 gsm.

[0025] Furthermore, the water-based foaming latex in step 1 is ethylene-vinyl acetate copolymer (EVA) water-based foaming latex.

[0026] Furthermore, the water-based foamed latex in step 1 has a dry glue weight of 80-100 gsm, a wet latex solid content of 30-50%, and a foaming ratio of 2-3 times.

[0027] Furthermore, the coating speed in step 1 is 8-12 m / min.

[0028] Furthermore, the drying temperature in step 1 is 180-200° C., and the drying time is 2-3 minutes.

[0029] Furthermore, in step 2, the mass volume ratio of the coconut shell charcoal to the concentrated nitric acid is (1:5)-(1:10).

[0030] Furthermore, the mesh size of the coconut shell charcoal in step 2 is 200-240 mesh.

[0031] Furthermore, the temperature of the low-temperature stirring in step 2 is -5 to 0°C, and the low-temperature stirring speed is 100-200 rpm.

[0032] Furthermore, the heating temperature in step 2 is 70-90°C.

[0033] Furthermore, the stirring speed of the stirring and acidification in step 2 is 300-450 rpm, and the stirring and acidification time is 3-4 hours.

[0034] Furthermore, the washing in step 2 is performed until the pH value of the washing solution is 6-7.

[0035] Furthermore, the drying temperature in step 2 is 120-140° C., and the drying time is 10-15 hours.

[0036] Furthermore, in step 3, the molar ratio of the activated coconut shell charcoal to the formaldehyde-removing crystals is (18-22):1.

[0037] Furthermore, the formaldehyde-removing crystal in step 3 is tetrabutyl titanate.

[0038] Furthermore, the stirring and dispersing speed in step 3 is 300-500 rpm, and the stirring and dispersing time is 10-15 min.

[0039] Furthermore, in step 3, the volume ratio of the anhydrous ethanol to the deionized water is 1:1.

[0040] Furthermore, the mass-to-volume ratio of the activated coconut shell charcoal to the anhydrous ethanol in step 3 is (1:5)-(1:6), wherein the unit of mass is g and the unit of volume is mL.

[0041] Furthermore, the ultrasonication time in step 3 is 10-20 minutes.

[0042] Furthermore, the hydrothermal reaction in step 3 is stirred at a speed of 300-500 rpm.

[0043] Furthermore, the temperature of the hydrothermal reaction in step 3 is 150-160° C., and the time of the hydrothermal reaction is 12-15 hours.

[0044] Furthermore, the drying temperature in step 3 is 120-150° C., and the drying time is 12-18 hours.

[0045] Furthermore, the calcination temperature in step 4 is 500-600° C., the calcination heating rate is 5° C. / min, and the calcination holding time is 1-1.5 h.

[0046] Furthermore, in step 4, the mass ratio of the loaded coconut shell charcoal to the compatibilizer and the polyethylene powder is (1:0.05:2)-(1:0.1:2).

[0047] Furthermore, the compatibilizer in step 4 is maleic anhydride grafted polyethylene.

[0048] Furthermore, the weight of the organic coconut shell charcoal in the adsorption layer in step 5 is 270-330 gsm.

[0049] Furthermore, the processing temperature of the adsorption layer in step 5 is 170-180°C.

[0050] Furthermore, the polyethylene-polyamide-polyethylene composite film in the reinforcement layer in step 5 has a gram weight of 180-200 gsm.

[0051] Furthermore, in step 5, the polyethylene-polyamide-polyethylene composite film and the polyethylene terephthalate needled felt are both laminated with polyethylene, the lamination temperature is 190-200° C., and the polyethylene weight is 200-500 gsm.

[0052] Furthermore, the polyethylene terephthalate needle-punched felt in the bottom layer in step 5 has a gram weight of 1000-1200 gsm.

[0053] The present invention also provides a low-odor car carpet, which is composed of the tufted carpet of the composite polymer coconut shell charcoal.

[0054] Beneficial effects of the present invention:

[0055] 1. The present invention reduces the odor and the content of organic matter, toxic and hazardous substances in the tufted carpet by compositely applying an adsorption layer to the back of the tufted carpet's adhesive layer. The adsorption layer comprises coconut shell charcoal, a compatibilizer, and polyethylene. The compatibilizer is maleic anhydride-grafted polyethylene. Its anhydride groups react with functional groups on the surface of the coconut shell charcoal, and its double bond functional groups are similarly compatible with polyethylene. This improves the compatibility of the coconut shell charcoal with polyethylene and the adhesive layer, thereby preventing the reduction in the adhesion of the tufted carpet due to the introduction of the coconut shell charcoal. In addition, polyethylene powder is molten and coated with organic coconut shell charcoal in the adsorption layer, enabling it to continuously adsorb organic matter and other substances in the tufted carpet. The coconut shell charcoal's inherent adsorption properties adsorb the organic matter, and the titanium dioxide loaded thereon subsequently decomposes the organic matter under photocatalysis, achieving a dynamic cycle of adsorption and decomposition, thereby reducing the organic matter content in the carpet. The combination of coconut shell charcoal and titanium dioxide allows the decomposition of organic matter in everyday sunlight without the need for special conditions, and other substances that cannot be decomposed are also adsorbed by the coconut shell charcoal.

[0056] 2. The coconut shell charcoal in the present invention has active functional groups on its surface after being acidified with nitric acid, which increases the active sites. When hydrothermally heated with tetrabutyl titanate, more titanium compounds can be grown in situ in the coconut shell charcoal. Tetrabutyl titanate gradually hydrolyzes in anhydrous ethanol and water solvents, and anhydrous ethanol provides an environment for slow hydrolysis of tetrabutyl titanate, thereby avoiding the aggregation of titanium dioxide after hydrolysis, resulting in uneven distribution on the coconut shell charcoal. In addition, the reaction is mild at the hydrothermal temperature in the present invention, which also avoids the aggregation of titanium dioxide. After the hydrothermal process, the coconut shell charcoal is further calcined, which improves the crystallinity of titanium dioxide and its interfacial bonding strength with the coconut shell charcoal, thereby avoiding shedding or uneven dispersion during subsequent mixing with a polymer, and also removes residual substances on the surface of the coconut shell charcoal during the hydrothermal process.

[0057] 3. The present invention achieves a tufted carpet with high mechanical strength, high adsorption, and low odor by using different materials and processing methods between different layers. The base fabric layer and the pile layer in the present invention are tufted at a high density by a tufting machine under specific process conditions. The pull-out force of the pile is also improved after bonding with water-based foamed latex. Since the latex contains a large amount of organic matter, an adsorption layer is compounded on the back of the adhesive layer at a specific temperature. Subsequently, a high-strength reinforcement layer is provided to improve the mechanical properties of the tufted carpet. Finally, a specific needling method is used to further improve the interlayer bonding strength, mechanical strength, and durability of the tufted carpet in the present invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0058] Figure 1 This is a peeling force test chart of the tufted carpet with composite polymer coconut shell charcoal of the present invention;

[0059] Figure 2This is a graph showing the breaking strength test of the tufted carpet with composite polymer coconut shell charcoal of the present invention;

[0060] Figure 3 This is a tearing strength test chart of the tufted carpet with composite polymer coconut shell charcoal of the present invention;

[0061] Figure 4 This is a low-temperature impact test chart of the tufted carpet with composite polymer coconut shell charcoal of the present invention. DETAILED DESCRIPTION

[0062] The invention is described in detail below with reference to the embodiments:

[0063] The present invention provides a tufted carpet composited with high-molecular coconut shell charcoal, a preparation method and an application thereof. The odor and organic matter content of the carpet are greatly reduced by composited with the adsorption layer prepared in the present invention, and the mechanical properties of the carpet are improved by composited with the adsorption layer.

[0064] Example 1

[0065] This embodiment provides a tufted carpet of composite polymer coconut shell charcoal. The tufted carpet of composite polymer coconut shell charcoal has a multi-layer structure, which comprises, from bottom to top, a base layer, a reinforcement layer, an adsorption layer, an adhesive layer, a base fabric layer, and a pile layer. The raw materials of the adsorption layer include polyethylene powder, formaldehyde-removing crystals, a compatibilizer, and coconut shell charcoal. The formaldehyde-removing crystals are loaded on the coconut shell charcoal, then mixed with the compatibilizer and polyethylene powder and then sprinkled on the adhesive layer. The adsorption layer is prepared at high temperature.

[0066] The thickness of the composite polymer coconut shell charcoal tufted carpet is 12.70 mm and the weight is 1996.20 g / m 2 , the number of cut pile loops is 2550 / 100cm 2 , the pile height is 4mm, and the tuft extraction force is 29.6N;

[0067] The tufted carpet of the composite polymer coconut shell charcoal has a peeling force of 66N, a weft breaking strength of 1388N / 5cm, a warp breaking strength of 1529N / 5cm, a weft tearing strength of 231.0N, and a warp tearing strength of 244.1N.

[0068] The tufted carpet of the composite polymer coconut shell charcoal has an odor level of 3.5 when kept at 80°C for 2 hours in a dry state, an odor level of 4.0 when kept at 40°C for 24 hours in a wet state, and an odor level of 4.5 when kept at 23°C for 24 hours in a wet state. The content of toxic and harmful substances is ≤1000 mg / kg, the content of cadmium is ≤100 mg / kg, and the content of polycyclic aromatic hydrocarbons is ≤0.2 mg / kg.

[0069] The formaldehyde content of the volatile organic matter content of the tufted carpet with composite polymer coconut shell charcoal is 18.63 μg / m 3 , acetaldehyde content is 48.28μg / m 3 , toluene content is 5.15μg / m 3 , while acrylic acid, acetone, benzene, ethylbenzene, xylene (o-m-p) and styrene were not detected; total volatile organic compounds (C6-C 16 ) content is 1114.27μg / m 3 ;

[0070] The tufted carpet made of composite high-molecular coconut shell charcoal has no cracks, no breakages and no delamination after a low-temperature impact test.

[0071] This embodiment also provides a method for preparing the composite polymer coconut shell charcoal tufted carpet, comprising the following steps:

[0072] Step 1. Tufting 350 gsm bulked continuous filament yarn (BCF yarn) onto a 120 gsm polyethylene terephthalate non-woven base fabric using a tufting machine, controlling the needle pitch of the tufting machine to 50.39 needles / 10 cm, the row spacing to 51 needles / 10 cm, the needling depth to 5.5 mm, and the needle frequency to 1000 RPM, to obtain a pile layer and a base fabric layer; and coating 200 gsm of ethylene-vinyl acetate copolymer (EVA) water-based foamed latex (dry glue weight of 80 gsm, wet latex solid content of 40%, and foaming ratio of 3 times) on the bottom of the base fabric layer at a speed of 10 m / min, and drying at 180° C. for 2 minutes to obtain an adhesive layer;

[0073] Step 2, adding concentrated nitric acid (with a mass volume ratio of 1:5 to the coconut shell charcoal) to the coconut shell charcoal (200 mesh) at 0°C and 200 rpm, gradually heating to 70°C, and stirring and acidifying at 350 rpm for 3 hours, washing the acidified coconut shell charcoal with deionized water until the pH of the filtrate is 7, and drying at 120°C for 12 hours after washing to obtain activated coconut shell charcoal;

[0074] Step 3, the activated coconut shell charcoal and tetrabutyl titanate with a molar ratio of 20:1 were stirred at 300 rpm for 10 minutes and dispersed in anhydrous ethanol and deionized water (the volume ratio of the anhydrous ethanol to the deionized water was 1:1, and the mass volume ratio of the activated coconut shell charcoal to the anhydrous ethanol was 1:5, where the unit of mass was g and the unit of volume was mL). After ultrasonication for 15 minutes, the reaction was carried out at 300 rpm and 150 ° C for 12 hours in a closed hydrothermal state. After cooling and filtering, the solid product was dried at 120 ° C for 12 hours to obtain in situ grown coconut shell charcoal;

[0075] Step 4, heating the in situ grown coconut shell charcoal to 500° C. at a rate of 5° C. / min for calcination, keeping the temperature for 1 hour, and then cooling to room temperature to obtain loaded coconut shell charcoal, and uniformly mixing the loaded coconut shell charcoal with maleic anhydride grafted polyethylene and polyethylene powder in a mass ratio of 1:0.05:2 to obtain organic coconut shell charcoal;

[0076] Step 5: Evenly sprinkle 300 gsm of the organic coconut shell charcoal on the back of the adhesive layer, heat it to 170°C to melt and bond the organic coconut shell charcoal to the back of the adhesive layer, and cool it to room temperature to obtain an adsorption layer. Continue to composite a polyethylene-polyamide-polyethylene composite film (PEPAPE film) on the back of the adsorption layer at a weight of 180 gsm, and cool it to room temperature to obtain a reinforcement layer. Composite a 1000 gsm polyethylene terephthalate (PET) needle-punched felt bottom layer on the back of the reinforcement layer. The composite method is to bond the polyethylene-polyamide-polyethylene composite film and the polyethylene terephthalate needle-punched felt with 200 gsm of polyethylene at 190°C to obtain the composite polymer coconut shell charcoal tufted carpet.

[0077] Example 2

[0078] This embodiment provides a tufted carpet of composite polymer coconut shell charcoal. The tufted carpet of composite polymer coconut shell charcoal has a multi-layer structure, which comprises, from bottom to top, a base layer, a reinforcement layer, an adsorption layer, an adhesive layer, a base fabric layer, and a pile layer. The raw materials of the adsorption layer include polyethylene powder, formaldehyde-removing crystals, a compatibilizer, and coconut shell charcoal. The formaldehyde-removing crystals are loaded on the coconut shell charcoal, then mixed with the compatibilizer and polyethylene powder and then sprinkled on the adhesive layer. The adsorption layer is prepared at high temperature.

[0079] The thickness of the composite polymer coconut shell charcoal tufted carpet is 12.84 mm and the weight is 1914.81 g / m 2 , the number of cut pile loops is 2660 / 100cm 2 , the pile height is 4mm, and the tuft extraction force is 27.3N;

[0080] The tufted carpet of the composite polymer coconut shell charcoal has a peeling force of 64N, a weft breaking strength of 1371N / 5cm, a warp breaking strength of 1578N / 5cm, a weft tearing strength of 249.9N, and a warp tearing strength of 279.6N.

[0081] The tufted carpet of the composite polymer coconut shell charcoal has an odor level of 4.0 when kept at 80°C for 2 hours in a dry state, 4.5 when kept at 40°C for 24 hours in a wet state, and 5.0 when kept at 23°C for 24 hours in a wet state. The content of toxic and harmful substances is ≤1000 mg / kg, the content of cadmium is ≤100 mg / kg, and the content of polycyclic aromatic hydrocarbons is ≤0.2 mg / kg.

[0082] The formaldehyde content of the volatile organic matter content of the tufted carpet with composite polymer coconut shell charcoal is 18.06 μg / m 3 , acetaldehyde content is 48.00μg / m 3 , toluene content is 5.12μg / m 3 , while acrylic acid, acetone, benzene, ethylbenzene, xylene (o-m-p) and styrene were not detected; total volatile organic compounds (C6-C 16 ) content is 1167.53μg / m 3 ;

[0083] The tufted carpet made of composite high-molecular coconut shell charcoal has no cracks, no breakages and no delamination after a low-temperature impact test.

[0084] This embodiment also provides a method for preparing the composite polymer coconut shell charcoal tufted carpet, comprising the following steps:

[0085] Step 1: tufting 400 gsm bulked continuous filament onto a 100 gsm polyethylene terephthalate non-woven base fabric using a tufting machine, controlling the needle pitch of the tufting machine to 50.39 needles / 10 cm, the row spacing to 50 needles / 10 cm, the needling depth to 5 mm, and the needle frequency to 1100 RPM, to obtain a pile layer and a base fabric layer; and coating 180 gsm of ethylene-vinyl acetate copolymer water-based foamed latex (dry glue weight of 90 gsm, wet latex solid content of 30%, and foaming ratio of 2) on the bottom of the base fabric layer at a speed of 8 m / min, and drying at 190° C. for 2.5 minutes to obtain an adhesive layer;

[0086] Step 2, adding concentrated nitric acid (with a mass volume ratio of 1:7 to the coconut shell charcoal) to the coconut shell charcoal (220 mesh) at -3 ° C and 150 rpm, gradually heating to 90 ° C, and stirring at 300 rpm for 3 hours, washing the acidified coconut shell charcoal with deionized water until the pH of the filtrate is 7, and drying at 120 ° C for 12 hours after washing to obtain activated coconut shell charcoal;

[0087] Step 3, the activated coconut shell charcoal and tetrabutyl titanate with a molar ratio of 18:1 were stirred at 400 rpm for 10 min and dispersed in anhydrous ethanol and deionized water (the volume ratio of the anhydrous ethanol to the deionized water was 1:1, and the mass volume ratio of the activated coconut shell charcoal to the anhydrous ethanol was 1:5, where the unit of mass was g and the unit of volume was mL). After ultrasonication for 18 min, the reaction was carried out at 300 rpm and 155 ° C for 12 h in a closed hydrothermal state. After cooling and filtration, the solid product was dried at 130 ° C for 12 h to obtain in situ grown coconut shell charcoal;

[0088] Step 4, heating the in situ grown coconut shell charcoal to 550° C. at a rate of 5° C. / min for calcination, keeping the temperature for 1 hour, and then cooling to room temperature to obtain loaded coconut shell charcoal, and uniformly mixing the loaded coconut shell charcoal with maleic anhydride grafted polyethylene and polyethylene powder in a mass ratio of 1:0.1:2 to obtain organic coconut shell charcoal;

[0089] Step 5: Evenly sprinkle the organic coconut shell charcoal on the back of the adhesive layer at 270 gsm, heat it to 170°C to melt and bond the organic coconut shell charcoal to the back of the adhesive layer, and cool it to room temperature to obtain an adsorption layer. Continue to composite a polyethylene-polyamide-polyethylene composite film (PEPAPE film) on the back of the adsorption layer at 180 gsm, and cool it to room temperature to obtain a reinforcement layer. Composite a 1200 gsm polyethylene terephthalate (PET) needle-punched felt bottom layer on the back of the reinforcement layer. The composite method is to bond the polyethylene-polyamide-polyethylene composite film and the polyethylene terephthalate needle-punched felt with 400 gsm polyethylene at 200°C to obtain the composite polymer coconut shell charcoal tufted carpet.

[0090] Example 3

[0091] This embodiment provides a tufted carpet of composite polymer coconut shell charcoal. The tufted carpet of composite polymer coconut shell charcoal has a multi-layer structure, which comprises, from bottom to top, a base layer, a reinforcement layer, an adsorption layer, an adhesive layer, a base fabric layer, and a pile layer. The raw materials of the adsorption layer include polyethylene powder, formaldehyde-removing crystals, a compatibilizer, and coconut shell charcoal. The formaldehyde-removing crystals are loaded on the coconut shell charcoal, then mixed with the compatibilizer and polyethylene powder and then sprinkled on the adhesive layer. The adsorption layer is prepared at high temperature.

[0092] The thickness of the composite polymer coconut shell charcoal tufted carpet is 12.56 mm and the weight is 1973.03 g / m 2 , the number of cut pile loops is 2550 / 100cm 2 , the pile height is 4mm, and the tuft extraction force is 26.7N;

[0093] The tufted carpet of the composite polymer coconut shell charcoal has a peeling force of 58N, a weft breaking strength of 1344N / 5cm, a warp breaking strength of 1589N / 5cm, a weft tearing strength of 264.6N, and a warp tearing strength of 239.0N.

[0094] The tufted carpet of the composite polymer coconut shell charcoal has an odor level of 4.0 when kept at 80°C for 2 hours in a dry state, 4.5 when kept at 40°C for 24 hours in a wet state, and 5.0 when kept at 23°C for 24 hours in a wet state. The content of toxic and harmful substances is ≤1000 mg / kg, the content of cadmium is ≤100 mg / kg, and the content of polycyclic aromatic hydrocarbons is ≤0.2 mg / kg.

[0095] The tufted carpet made of composite high-molecular coconut shell charcoal has no cracks, no breakages and no delamination after a low-temperature impact test.

[0096] This embodiment also provides a method for preparing the composite polymer coconut shell charcoal tufted carpet, comprising the following steps:

[0097] Step 1. Tufting 450 gsm bulked continuous filaments onto a 110 gsm polyethylene terephthalate non-woven base fabric using a tufting machine, controlling the needle pitch of the tufting machine to 50.39 needles / 10 cm, the row spacing to 52 needles / 10 cm, the needling depth to 6 mm, and the needle frequency to 1200 RPM, to obtain a pile layer and a base fabric layer; and coating 190 gsm of ethylene-vinyl acetate copolymer water-based foamed latex (dry glue weight of 100 gsm, wet latex solid content of 50%, and foaming ratio of 3 times) on the bottom of the base fabric layer at a speed of 8 m / min, and drying at 200° C. for 2 minutes to obtain an adhesive layer;

[0098] Step 2, adding concentrated nitric acid (with a mass volume ratio of 1:10 to the coconut shell charcoal) to the coconut shell charcoal (240 mesh) at -5 ° C and 100 rpm, gradually heating to 80 ° C, and stirring at 400 rpm for 3 hours, washing the acidified coconut shell charcoal with deionized water until the pH of the filtrate is 6, and drying at 130 ° C for 15 hours after washing to obtain activated coconut shell charcoal;

[0099] Step 3, the activated coconut shell charcoal and tetrabutyl titanate with a molar ratio of 22:1 were stirred at 500 rpm for 10 minutes and dispersed in anhydrous ethanol and deionized water (the volume ratio of the anhydrous ethanol to the deionized water was 1:1, and the mass volume ratio of the activated coconut shell charcoal to the anhydrous ethanol was 1:6, where the unit of mass was g and the unit of volume was mL). After ultrasonication for 20 minutes, the reaction was carried out at 500 rpm and 150° C. for 15 hours in a closed hydrothermal state. After cooling and filtration, the solid product was dried at 140° C. for 15 hours to obtain in situ grown coconut shell charcoal;

[0100] Step 4, heating the in situ grown coconut shell charcoal to 600° C. at a rate of 5° C. / min for calcination, keeping the temperature for 1.5 hours, and then cooling to room temperature to obtain loaded coconut shell charcoal, and uniformly mixing the loaded coconut shell charcoal with maleic anhydride grafted polyethylene and polyethylene powder in a mass ratio of 1:0.1:2 to obtain organic coconut shell charcoal;

[0101] Step 5: Evenly sprinkle the organic coconut shell charcoal on the back of the adhesive layer at 330 gsm, heat it to 180°C to melt and bond the organic coconut shell charcoal to the back of the adhesive layer, and cool it to room temperature to obtain an adsorption layer. Continue to composite a polyethylene-polyamide-polyethylene composite film (PEPAPE film) on the back of the adsorption layer at 180 gsm, and cool it to room temperature to obtain a reinforcement layer. Composite a 1100 gsm polyethylene terephthalate (PET) needle-punched felt bottom layer on the back of the reinforcement layer. The composite method is to bond the polyethylene-polyamide-polyethylene composite film and the polyethylene terephthalate needle-punched felt with 200 gsm polyethylene at 190°C to obtain the composite polymer coconut shell charcoal tufted carpet.

[0102] Example 4

[0103] This embodiment provides a tufted carpet of composite polymer coconut shell charcoal. The tufted carpet of composite polymer coconut shell charcoal has a multi-layer structure, which comprises, from bottom to top, a base layer, a reinforcement layer, an adsorption layer, an adhesive layer, a base fabric layer, and a pile layer. The raw materials of the adsorption layer include polyethylene powder, formaldehyde-removing crystals, a compatibilizer, and coconut shell charcoal. The formaldehyde-removing crystals are loaded on the coconut shell charcoal, then mixed with the compatibilizer and polyethylene powder and then sprinkled on the adhesive layer. The adsorption layer is prepared at high temperature.

[0104] The thickness of the composite polymer coconut shell charcoal tufted carpet is 12.82 mm and the weight is 1956.14 g / m 2 , the tuft extraction force is 26.1N;

[0105] The tufted carpet of the composite polymer coconut shell charcoal has a peeling force of 61N, a weft breaking strength of 1404N / 5cm, a warp breaking strength of 1616N / 5cm, a weft tearing strength of 220.7N, and a warp tearing strength of 219.9N.

[0106] The tufted carpet of the composite polymer coconut shell charcoal has an odor level of 4.0 when kept at 80°C for 2 hours in a dry state, 4.5 when kept at 40°C for 24 hours in a wet state, and 5.0 when kept at 23°C for 24 hours in a wet state. The content of toxic and harmful substances is ≤1000 mg / kg, the content of cadmium is ≤100 mg / kg, and the content of polycyclic aromatic hydrocarbons is ≤0.2 mg / kg.

[0107] The tufted carpet made of composite high-molecular coconut shell charcoal has no cracks, no breakages and no delamination after a low-temperature impact test.

[0108] This embodiment also provides a method for preparing the composite polymer coconut shell charcoal tufted carpet, comprising the following steps:

[0109] Step 1: tufting 500 gsm of bulked continuous filament onto a 120 gsm polyethylene terephthalate non-woven base fabric using a tufting machine, controlling the needle pitch of the tufting machine to 50.39 needles / 10 cm, the row spacing to 54 needles / 10 cm, the needling depth to 5.5 mm, and the needle frequency to 1300 RPM, to obtain a pile layer and a base fabric layer; and applying 200 gsm of ethylene-vinyl acetate copolymer water-based foamed latex (dry glue weight of 80 gsm, wet latex solid content of 30%, and foaming ratio of 3 times) to the bottom of the base fabric layer at a speed of 12 m / min, and drying at 200° C. for 2.5 minutes to obtain an adhesive layer;

[0110] Step 2, adding concentrated nitric acid (with a mass volume ratio of 1:5 to the coconut shell charcoal) to the coconut shell charcoal (200 mesh) at 0°C and 100 rpm, gradually heating to 80°C, and stirring and acidifying at 450 rpm for 3 hours, washing the acidified coconut shell charcoal with deionized water until the pH of the filtrate is 7, and drying at 140°C for 10 hours after washing to obtain activated coconut shell charcoal;

[0111] Step 3, the activated coconut shell charcoal and tetrabutyl titanate with a molar ratio of 20:1 were stirred at 300 rpm for 15 minutes and dispersed in anhydrous ethanol and deionized water (the volume ratio of the anhydrous ethanol to the deionized water was 1:1, and the mass volume ratio of the activated coconut shell charcoal to the anhydrous ethanol was 1:5, where the unit of mass was g and the unit of volume was mL). After ultrasonication for 10 minutes, the reaction was carried out at 300 rpm and 160°C for 12 hours in a closed hydrothermal state. After cooling and filtration, the solid product was dried at 150°C for 12 hours to obtain in situ grown coconut shell charcoal;

[0112] Step 4, heating the in situ grown coconut shell charcoal to 500° C. at a rate of 5° C. / min for calcination, keeping the temperature for 1.5 hours, and then cooling to room temperature to obtain loaded coconut shell charcoal, and uniformly mixing the loaded coconut shell charcoal with maleic anhydride grafted polyethylene and polyethylene powder in a mass ratio of 1:0.05:2 to obtain organic coconut shell charcoal;

[0113] Step 5: Evenly sprinkle 300 gsm of the organic coconut shell charcoal on the back of the adhesive layer, heat it to 170°C to melt and bond the organic coconut shell charcoal to the back of the adhesive layer, and cool it to room temperature to obtain an adsorption layer. Continue to composite a polyethylene-polyamide-polyethylene composite film (PEPAPE film) on the back of the adsorption layer at a gram weight of 190 gsm, and cool it to room temperature to obtain a reinforcement layer. Composite a 1000 gsm polyethylene terephthalate (PET) needle-punched felt bottom layer on the back of the reinforcement layer. The composite method is to bond the polyethylene-polyamide-polyethylene composite film and the polyethylene terephthalate needle-punched felt with 500 gsm of polyethylene at 200°C to obtain the composite polymer coconut shell charcoal tufted carpet.

[0114] Example 5

[0115] This embodiment provides a tufted carpet of composite polymer coconut shell charcoal. The tufted carpet of composite polymer coconut shell charcoal has a multi-layer structure, which comprises, from bottom to top, a base layer, a reinforcement layer, an adsorption layer, an adhesive layer, a base fabric layer, and a pile layer. The raw materials of the adsorption layer include polyethylene powder, formaldehyde-removing crystals, a compatibilizer, and coconut shell charcoal. The formaldehyde-removing crystals are loaded on the coconut shell charcoal, then mixed with the compatibilizer and polyethylene powder and then sprinkled on the adhesive layer. The adsorption layer is prepared at high temperature.

[0116] The thickness of the composite polymer coconut shell charcoal tufted carpet is 12.48 mm and the weight is 1938.22 g / m 2 , the tuft extraction force is 27.2N;

[0117] The tufted carpet of the composite polymer coconut shell charcoal has a peeling force of 66N, a weft breaking strength of 1404N / 5cm, a warp breaking strength of 1623N / 5cm, a weft tearing strength of 212.1N, and a warp tearing strength of 211.1N.

[0118] The tufted carpet of the composite polymer coconut shell charcoal has an odor level of 4.0 when kept at 80°C for 2 hours in a dry state, 4.5 when kept at 40°C for 24 hours in a wet state, and 5.0 when kept at 23°C for 24 hours in a wet state. The content of toxic and harmful substances is ≤1000 mg / kg, the content of cadmium is ≤100 mg / kg, and the content of polycyclic aromatic hydrocarbons is ≤0.2 mg / kg.

[0119] The tufted carpet made of composite high-molecular coconut shell charcoal has no cracks, no breakages and no delamination after a low-temperature impact test.

[0120] This embodiment also provides a method for preparing the composite polymer coconut shell charcoal tufted carpet, comprising the following steps:

[0121] Step 1. Tufting 350 gsm bulked continuous filaments onto a 120 gsm polyethylene terephthalate non-woven base fabric using a tufting machine, controlling the needle pitch of the tufting machine to 50.39 needles / 10 cm, the row spacing to 55 needles / 10 cm, the needling depth to 5.5 mm, and the needle frequency to 1000 RPM, to obtain a pile layer and a base fabric layer; and coating 200 gsm of ethylene-vinyl acetate copolymer water-based foamed latex (dry glue weight of 80 gsm, wet latex solid content of 40%, and foaming ratio of 3 times) on the bottom of the base fabric layer at a speed of 10 m / min, and drying at 180° C. for 2.5 minutes to obtain an adhesive layer;

[0122] Step 2, adding concentrated nitric acid (with a mass volume ratio of 1:5 to the coconut shell charcoal) to the coconut shell charcoal (200 mesh) at 0°C and 100 rpm, gradually heating to 80°C, and stirring and acidifying at 300 rpm for 4 hours, washing the acidified coconut shell charcoal with deionized water until the pH of the filtrate is 7, and drying at 140°C for 10 hours after washing to obtain activated coconut shell charcoal;

[0123] Step 3, the activated coconut shell charcoal and tetrabutyl titanate with a molar ratio of 20:1 were stirred at 300 rpm for 10 minutes and dispersed in anhydrous ethanol and deionized water (the volume ratio of the anhydrous ethanol to the deionized water was 1:1, and the mass volume ratio of the activated coconut shell charcoal to the anhydrous ethanol was 1:5, where the unit of mass was g and the unit of volume was mL). After ultrasonication for 15 minutes, the reaction was carried out at 300 rpm and 150 ° C for 12 hours in a closed hydrothermal state. After cooling and filtering, the solid product was dried at 120 ° C for 18 hours to obtain in situ grown coconut shell charcoal;

[0124] Step 4, heating the in situ grown coconut shell charcoal to 500° C. at a rate of 5° C. / min for calcination, keeping the temperature for 1 hour, and then cooling to room temperature to obtain loaded coconut shell charcoal, and uniformly mixing the loaded coconut shell charcoal with maleic anhydride grafted polyethylene and polyethylene powder in a mass ratio of 1:0.1:2 to obtain organic coconut shell charcoal;

[0125] Step 5: Evenly sprinkle 300 gsm of the organic coconut shell charcoal on the back of the adhesive layer, heat it to 170°C to melt and bond the organic coconut shell charcoal to the back of the adhesive layer, and cool it to room temperature to obtain an adsorption layer. Continue to composite a polyethylene-polyamide-polyethylene composite film (PEPAPE film) on the back of the adsorption layer at a weight of 200 gsm, and cool it to room temperature to obtain a reinforcement layer. Composite a 1000 gsm polyethylene terephthalate (PET) needle-punched felt bottom layer on the back of the reinforcement layer. The composite method is to bond the polyethylene-polyamide-polyethylene composite film and the polyethylene terephthalate needle-punched felt with 200 gsm of polyethylene at 190°C to obtain the composite polymer coconut shell charcoal tufted carpet.

[0126] Comparative Example 1

[0127] This comparative example provides a composite tufted carpet, which has a multi-layer structure, comprising, from bottom to top, a base layer, a reinforcement layer, an adhesive layer, a base fabric layer, and a pile layer;

[0128] The composite tufted carpet has a thickness of 7 mm and a gram weight of 1790.01 g / m 2 , the number of cut pile loops is 2821 / 100cm 2 , the pile height is 4.5mm, and the tuft extraction force is 15N;

[0129] The composite tufted carpet has a peeling force of 42N, a weft breaking strength of 1246N / 5cm, a warp breaking strength of 1324N / 5cm, a weft tearing strength of 178N, and a warp tearing strength of 183N.

[0130] The composite tufted carpet has an odor level of 3 when kept at 80°C for 2 hours in a dry state, a odor level of 3.5 when kept at 40°C for 24 hours in a wet state, and a odor level of 3.5 when kept at 23°C for 24 hours in a wet state. The content of toxic and harmful substances is ≤1000 mg / kg, the content of cadmium is ≤1000 mg / kg, and the content of polycyclic aromatic hydrocarbons is ≤10 mg / kg.

[0131] The formaldehyde content in the volatile organic matter content of the composite tufted carpet is 188.28 μg / m 3 , acetaldehyde content is 335.31μg / m 3 , toluene content is 52.41μg / m 3 , ethylbenzene content is 15.17μg / m 3 , xylene content is 66.09μg / m 3 , the acetone content is 143.24μg / m 3 , total volatile organic compounds (C6-C 16 ) content is 20124.04μg / m 3 , butyl acetate content is 72.92μg / m 3 , benzene content is 5.69μg / m 3 , styrene content is 3.91μg / m 3 ;

[0132] The composite tufted carpet is free of cracks, breaks and delamination after a low-temperature impact test.

[0133] This comparative example also provides a method for preparing the composite tufted carpet, comprising the following steps:

[0134] Step 1. Tufting 350 gsm bulked continuous filament yarn (BCF yarn) onto a 120 gsm polyethylene terephthalate non-woven base fabric using a tufting machine, controlling the needle pitch of the tufting machine to 50.39 needles / 10 cm, the row spacing to 51 needles / 10 cm, the needling depth to 5.5 mm, and the needle frequency to 1000 RPM, to obtain a pile layer and a base fabric layer; and coating 200 gsm of ethylene-vinyl acetate copolymer (EVA) water-based foamed latex (dry glue weight of 80 gsm, wet latex solid content of 40%, and foaming ratio of 3 times) on the bottom of the base fabric layer at a speed of 12 m / min, and drying at 180° C. for 2.5 minutes to obtain an adhesive layer;

[0135] Step 2: A polyethylene-polyamide-polyethylene composite film (PEPAPE film) having a weight of 180 gsm is laminated on the back of the adhesive layer, and after cooling to room temperature, a reinforcement layer is obtained. A 1000 gsm polyethylene terephthalate (PET) needle-punched felt bottom layer is laminated on the back of the reinforcement layer. The polyethylene-polyamide-polyethylene composite film and the polyethylene terephthalate needle-punched felt are respectively bonded with 200 gsm polyethylene at 190° C. to obtain the composite tufted carpet.

[0136] Comparative Example 2

[0137] This comparative example provides a tufted carpet made of composite coconut shell charcoal. The tufted carpet made of composite coconut shell charcoal has a multi-layer structure, which comprises, from bottom to top, a base layer, a reinforcement layer, an adsorption layer, an adhesive layer, a base fabric layer, and a pile layer. The raw materials in the adsorption layer include polyethylene powder and coconut shell charcoal.

[0138] The thickness of the composite coconut shell charcoal tufted carpet is 8mm and the weight is 1981.25g / m 2 , the number of cut pile loops is 2700 / 100cm 2 , the pile height is 4mm, and the tuft extraction force is 19N;

[0139] The tufted carpet of the composite coconut shell charcoal has a peeling force of 39N, a weft breaking strength of 1152N / 5cm, a warp breaking strength of 1290N / 5cm, a weft tearing strength of 171N, and a warp tearing strength of 179N.

[0140] The odor level of the composite coconut shell charcoal tufted carpet is 3.5 when kept at 80°C for 2 hours in a dry state, 4 when kept at 40°C for 24 hours in a wet state, and 4 when kept at 23°C for 24 hours in a wet state. The content of toxic and harmful substances is ≤1000 mg / kg, the content of cadmium is ≤1000 mg / kg, and the content of polycyclic aromatic hydrocarbons is ≤10 mg / kg.

[0141] The formaldehyde content of the volatile organic matter content of the tufted carpet of the composite coconut shell charcoal is 99.76 μg / m 3 , acetaldehyde content is 111.58μg / m 3 , acetone content is 32.61μg / m 3 、Total volatile organic compounds (TVOC, C6-C 16 ) content is 3261.75μg / m 3 Toluene, ethylbenzene, xylene (o-m-p), butyl acetate, benzene and styrene were not detected;

[0142] The tufted carpet made of composite coconut shell charcoal has no cracks, no breakage and no delamination after a low-temperature impact test.

[0143] This comparative example also provides a method for preparing the composite coconut shell charcoal tufted carpet, comprising the following steps:

[0144] Step 1. Tufting 350 gsm bulked continuous filament yarn (BCF yarn) onto a 120 gsm polyethylene terephthalate non-woven base fabric using a tufting machine, controlling the needle pitch of the tufting machine to 50.39 needles / 10 cm, the row spacing to 51 needles / 10 cm, the needling depth to 5.5 mm, and the needle frequency to 1000 RPM, to obtain a pile layer and a base fabric layer; and coating 200 gsm of ethylene-vinyl acetate copolymer (EVA) water-based foamed latex (dry glue weight of 80 gsm, wet latex solid content of 40%, and foaming ratio of 3 times) on the bottom of the base fabric layer at a speed of 10 m / min, and drying at 180° C. for 2.5 minutes to obtain an adhesive layer;

[0145] Step 2, adding concentrated nitric acid (with a mass volume ratio of 1:5 to the coconut shell charcoal) to the coconut shell charcoal (200 mesh) at 0°C and 200 rpm, gradually heating to 70°C, and stirring and acidifying at 350 rpm for 3 hours, washing the acidified coconut shell charcoal with deionized water until the pH of the filtrate is 7, and drying at 120°C for 12 hours after washing to obtain activated coconut shell charcoal;

[0146] Step 3, uniformly mixing the activated coconut shell charcoal and polyethylene powder in a mass ratio of 1:2 to obtain organic coconut shell charcoal;

[0147] Step 4: Evenly sprinkle 300 gsm of the organic coconut shell charcoal on the back of the adhesive layer, heat it to 170°C to melt and bond the organic coconut shell charcoal to the back of the adhesive layer, and cool it to room temperature to obtain an adsorption layer. Continue to composite a polyethylene-polyamide-polyethylene composite film (PEPAPE film) on the back of the adsorption layer at a weight of 180 gsm, and cool it to room temperature to obtain a reinforcement layer. Composite a 1000 gsm polyethylene terephthalate (PET) needle-punched felt bottom layer on the back of the reinforcement layer. The composite method is to bond the polyethylene-polyamide-polyethylene composite film and the polyethylene terephthalate needle-punched felt with 200 gsm of polyethylene at 190°C to obtain the composite coconut shell charcoal tufted carpet.

[0148] Comparative Example 3

[0149] This comparative example provides a tufted carpet made of composite coconut shell charcoal. The tufted carpet made of composite coconut shell charcoal has a multi-layer structure, which comprises, from bottom to top, a base layer, a reinforcement layer, an adsorption layer, an adhesive layer, a base fabric layer, and a pile layer.

[0150] The thickness of the composite coconut shell charcoal tufted carpet is 8 mm and the weight is 1863.11 g / m 2 , the number of cut pile loops is 2793 / 100cm2 , the pile height is 4mm, and the tuft extraction force is 22N;

[0151] The tufted carpet of the composite coconut shell charcoal has a peeling force of 45N, a weft breaking strength of 1097N / 5cm, a warp breaking strength of 1175N / 5cm, a weft tearing strength of 169N, and a warp tearing strength of 176N.

[0152] The odor level of the composite coconut shell charcoal tufted carpet is level 3 when kept at 80°C for 2 hours in a dry state, level 4 when kept at 40°C for 24 hours in a wet state, and level 4 when kept at 23°C for 24 hours in a wet state. The content of toxic and harmful substances is ≤1000 mg / kg, the content of cadmium is ≤1000 mg / kg, and the content of polycyclic aromatic hydrocarbons is ≤10 mg / kg.

[0153] The formaldehyde content of the volatile organic matter content of the tufted carpet of the composite coconut shell charcoal is 71.55 μg / m 3 , acetaldehyde content is 101.21μg / m 3 , acetone content is 10.63μg / m 3 、Total volatile organic compounds (TVOC, C6-C 16 ) content is 1792.00μg / m 3 Toluene, ethylbenzene, xylene (o-m-p), butyl acetate, benzene and styrene were not detected;

[0154] The tufted carpet made of composite coconut shell charcoal has no cracks, no breakage and no delamination after a low-temperature impact test.

[0155] This comparative example also provides a method for preparing the composite coconut shell charcoal tufted carpet, comprising the following steps:

[0156] Step 1. Tufting 350 gsm bulked continuous filament yarn (BCF yarn) onto a 120 gsm polyethylene terephthalate non-woven base fabric using a tufting machine, controlling the needle pitch of the tufting machine to 50.39 needles / 10 cm, the row spacing to 51 needles / 10 cm, the needling depth to 5.5 mm, and the needle frequency to 1000 RPM, to obtain a pile layer and a base fabric layer; and coating 200 gsm of ethylene-vinyl acetate copolymer (EVA) water-based foamed latex (dry glue weight of 80 gsm, wet latex solid content of 40%, and foaming ratio of 3 times) on the bottom of the base fabric layer at a speed of 10 m / min, and drying at 180° C. for 2.5 minutes to obtain an adhesive layer;

[0157] Step 2, coconut shell charcoal (200 mesh) and tetrabutyl titanate with a molar ratio of 20:1 were stirred at 300 rpm for 10 minutes and dispersed in anhydrous ethanol and deionized water (the volume ratio of the anhydrous ethanol to the deionized water was 1:1, and the mass volume ratio of the coconut shell charcoal to the anhydrous ethanol was 1:5, where the unit of mass was g and the unit of volume was mL). After ultrasonication for 15 minutes, the reaction was carried out at 300 rpm and 150 ° C for 12 hours in a closed hydrothermal state. After cooling and filtering, the solid product was dried at 120 ° C for 12 hours to obtain in situ grown coconut shell charcoal;

[0158] Step 3, heating the in situ grown coconut shell charcoal to 500° C. at a rate of 5° C. / min for calcination, keeping the temperature for 1 hour, and then cooling to room temperature to obtain loaded coconut shell charcoal, and uniformly mixing the loaded coconut shell charcoal with maleic anhydride grafted polyethylene and polyethylene powder in a mass ratio of 1:0.05:2 to obtain organic coconut shell charcoal;

[0159] Step 4: Evenly sprinkle 300 gsm of the organic coconut shell charcoal on the back of the adhesive layer, heat it to 170°C to melt and bond the organic coconut shell charcoal to the back of the adhesive layer, and cool it to room temperature to obtain an adsorption layer. Continue to composite a polyethylene-polyamide-polyethylene composite film (PEPAPE film) on the back of the adsorption layer at a gram weight of 180 gsm, and cool it to room temperature to obtain a reinforcement layer. Composite a 1000 gsm polyethylene terephthalate (PET) needle-punched felt bottom layer on the back of the reinforcement layer. The composite method is to bond the polyethylene-polyamide-polyethylene composite film and the polyethylene terephthalate needle-punched felt with 200 gsm of polyethylene at 190°C to obtain the composite polymer coconut shell charcoal tufted carpet.

[0160] Comparative Example 4

[0161] This comparative example provides a tufted carpet made of composite coconut shell charcoal. The tufted carpet made of composite coconut shell charcoal has a multi-layer structure, which comprises, from bottom to top, a base layer, a reinforcement layer, an adsorption layer, an adhesive layer, a base fabric layer, and a pile layer.

[0162] The thickness of the composite coconut shell charcoal tufted carpet is 8mm and the weight is 1822.67g / m 2 , the number of cut pile loops is 2665 / 100cm 2 , the pile height is 4mm, and the tuft extraction force is 23N;

[0163] The tufted carpet of the composite coconut shell charcoal has a peeling force of 43N, a weft breaking strength of 1090N / 5cm, a warp breaking strength of 1128N / 5cm, a weft tearing strength of 175N, and a warp tearing strength of 172N.

[0164] The odor level of the composite coconut shell charcoal tufted carpet is 3.5 when kept at 80°C for 2 hours in a dry state, 4 when kept at 40°C for 24 hours in a wet state, and 4 when kept at 23°C for 24 hours in a wet state. The content of toxic and harmful substances is ≤1000 mg / kg, the content of cadmium is ≤1000 mg / kg, and the content of polycyclic aromatic hydrocarbons is ≤10 mg / kg.

[0165] The formaldehyde content of the volatile organic matter content of the tufted carpet of the composite coconut shell charcoal is 82.50 μg / m 3 , acetaldehyde content is 121.10μg / m 3 , acetone content is 21.65μg / m 3 、Total volatile organic compounds (C6-C 16 ) content is 1507.57μg / m 3 Toluene, ethylbenzene, xylene (o-m-p), butyl acetate, benzene and styrene were not detected;

[0166] The tufted carpet made of composite coconut shell charcoal has no cracks, no breakage and no delamination after a low-temperature impact test.

[0167] This comparative example also provides a method for preparing the composite coconut shell charcoal tufted carpet, comprising the following steps:

[0168] Step 1. Tufting 350 gsm bulked continuous filament yarn (BCF yarn) onto a 120 gsm polyethylene terephthalate non-woven base fabric using a tufting machine, controlling the needle pitch of the tufting machine to 50.39 needles / 10 cm, the row spacing to 51 needles / 10 cm, the needling depth to 5.5 mm, and the needle frequency to 1000 RPM, to obtain a pile layer and a base fabric layer; and coating 200 gsm of ethylene-vinyl acetate copolymer (EVA) water-based foamed latex (dry glue weight of 80 gsm, wet latex solid content of 40%, and foaming ratio of 3 times) on the bottom of the base fabric layer at a speed of 10 m / min, and drying at 180° C. for 2.5 minutes to obtain an adhesive layer;

[0169] Step 2, adding concentrated nitric acid (with a mass volume ratio of 1:5 to the coconut shell charcoal) to the coconut shell charcoal (200 mesh) at 0°C and 200 rpm, gradually heating to 70°C, and stirring and acidifying at 350 rpm for 3 hours, washing the acidified coconut shell charcoal with deionized water until the pH of the filtrate is 7, and drying at 120°C for 12 hours after washing to obtain activated coconut shell charcoal;

[0170] Step 3, the activated coconut shell charcoal and tetrabutyl titanate with a molar ratio of 20:1 were stirred at 300 rpm for 10 minutes and dispersed in deionized water (the mass volume ratio of the activated coconut shell charcoal to the deionized water was 1:5, where the mass was in g and the volume was in mL), ultrasonicated for 15 minutes, and then hydrothermally sealed at 300 rpm and 300 ° C for 12 hours to react. After cooling and filtering, the solid product was dried at 120 ° C for 12 hours to obtain in situ grown coconut shell charcoal;

[0171] Step 4, heating the in situ grown coconut shell charcoal to 500° C. at a rate of 5° C. / min for calcination, keeping the temperature for 1 hour, and then cooling to room temperature to obtain loaded coconut shell charcoal, and uniformly mixing the loaded coconut shell charcoal with maleic anhydride grafted polyethylene and polyethylene powder in a mass ratio of 1:0.05:2 to obtain organic coconut shell charcoal;

[0172] Step 5: Evenly sprinkle 300 gsm of the organic coconut shell charcoal on the back of the adhesive layer, heat it to 170°C to melt and bond the organic coconut shell charcoal to the back of the adhesive layer, and cool it to room temperature to obtain an adsorption layer. Continue to composite a polyethylene-polyamide-polyethylene composite film (PEPAPE film) on the back of the adsorption layer at a weight of 180 gsm, and cool it to room temperature to obtain a reinforcement layer. Composite a 1000 gsm polyethylene terephthalate (PET) needle-punched felt bottom layer on the back of the reinforcement layer. The composite method is to bond the polyethylene-polyamide-polyethylene composite film and the polyethylene terephthalate needle-punched felt with 200 gsm of polyethylene at 190°C to obtain the composite polymer coconut shell charcoal tufted carpet.

[0173] Comparative Example 5

[0174] This comparative example provides a tufted carpet made of composite coconut shell charcoal. The tufted carpet made of composite coconut shell charcoal has a multi-layer structure, which comprises, from bottom to top, a base layer, a reinforcement layer, an adsorption layer, an adhesive layer, a base fabric layer, and a pile layer.

[0175] The thickness of the composite coconut shell charcoal tufted carpet is 8mm and the weight is 1859.28g / m 2 , the number of cut pile loops is 2660 / 100cm 2 , the pile height is 4mm, and the tuft extraction force is 29N;

[0176] The tufted carpet of the composite coconut shell charcoal has a peeling force of 44N, a weft breaking strength of 1121N / 5cm, a warp breaking strength of 1164N / 5cm, a weft tearing strength of 164N, and a warp tearing strength of 171N.

[0177] The odor level of the composite coconut shell charcoal tufted carpet is 3.5 when kept at 80°C for 2 hours in a dry state, 4 when kept at 40°C for 24 hours in a wet state, and 4 when kept at 23°C for 24 hours in a wet state. The content of toxic and harmful substances is ≤1000 mg / kg, the content of cadmium is ≤1000 mg / kg, and the content of polycyclic aromatic hydrocarbons is ≤10 mg / kg.

[0178] The formaldehyde content of the volatile organic matter content of the tufted carpet of the composite coconut shell charcoal is 65.28 μg / m 3 , acetaldehyde content is 105.95μg / m 3 , acetone content is 45.16μg / m 3 、Total volatile organic compounds (TVOC, C6-C 16 ) content was 111.92 μg / m 3 Toluene, ethylbenzene, xylene (o-m-p), butyl acetate, benzene and styrene were not detected;

[0179] The tufted carpet made of composite coconut shell charcoal has no cracks, no breakage and no delamination after a low-temperature impact test.

[0180] This comparative example also provides a method for preparing the composite coconut shell charcoal tufted carpet, comprising the following steps:

[0181] Step 1. Tufting 350 gsm bulked continuous filament yarn (BCF yarn) onto a 120 gsm polyethylene terephthalate non-woven base fabric using a tufting machine, controlling the needle pitch of the tufting machine to 50.39 needles / 10 cm, the row spacing to 51 needles / 10 cm, the needling depth to 5.5 mm, and the needle frequency to 1000 RPM, to obtain a pile layer and a base fabric layer; and coating 200 gsm of ethylene-vinyl acetate copolymer (EVA) water-based foamed latex (dry glue weight of 80 gsm, wet latex solid content of 40%, and foaming ratio of 3 times) on the bottom of the base fabric layer at a speed of 10 m / min, and drying at 180° C. for 2.5 minutes to obtain an adhesive layer;

[0182] Step 2, adding concentrated nitric acid (with a mass volume ratio of 1:5 to the coconut shell charcoal) to the coconut shell charcoal (200 mesh) at 0°C and 200 rpm, gradually heating to 70°C, and stirring and acidifying at 350 rpm for 3 hours, washing the acidified coconut shell charcoal with deionized water until the pH of the filtrate is 7, and drying at 120°C for 12 hours after washing to obtain activated coconut shell charcoal;

[0183] Step 3, the activated coconut shell charcoal and tetrabutyl titanate with a molar ratio of 20:1 were stirred at 300 rpm for 10 minutes and dispersed in anhydrous ethanol and deionized water (the volume ratio of the anhydrous ethanol to the deionized water was 1:1, and the mass volume ratio of the activated coconut shell charcoal to the anhydrous ethanol was 1:5, where the unit of mass was g and the unit of volume was mL). After ultrasonication for 15 minutes, the reaction was carried out at 300 rpm and 150 ° C for 12 hours in a closed hydrothermal state. After cooling and filtering, the solid product was dried at 120 ° C for 12 hours to obtain in situ grown coconut shell charcoal;

[0184] Step 4, uniformly mixing the in-situ grown coconut shell charcoal with maleic anhydride grafted polyethylene and polyethylene powder in a mass ratio of 1:0.05:2 to obtain organic coconut shell charcoal;

[0185] Step 5: Evenly sprinkle 300 gsm of the organic coconut shell charcoal on the back of the adhesive layer, heat it to 170°C to melt and bond the organic coconut shell charcoal to the back of the adhesive layer, and cool it to room temperature to obtain an adsorption layer. Continue to composite a polyethylene-polyamide-polyethylene composite film (PEPAPE film) on the back of the adsorption layer at a weight of 180 gsm, and cool it to room temperature to obtain a reinforcement layer. Composite a 1000 gsm polyethylene terephthalate (PET) needle-punched felt bottom layer on the back of the reinforcement layer. The composite method is to bond the polyethylene-polyamide-polyethylene composite film and the polyethylene terephthalate needle-punched felt with 200 gsm of polyethylene at 190°C to obtain the composite polymer coconut shell charcoal tufted carpet.

[0186] Performance of the tufted carpets of the composite polymer coconut shell charcoal described in Examples 1-5 of the present invention

[0187]

[0188] The content of volatile organic compounds in the tufted carpets of the composite polymer coconut shell charcoal in Examples 1 and 2 of the present invention (μg / m 3 )

[0189]

[0190] Performance of the tufted carpets described in Comparative Examples 1-5 of the present invention

[0191]

[0192] The content of volatile organic compounds in the tufted carpets described in Comparative Examples 1-5 of the present invention (μg / m 3 )

[0193]

[0194] As shown in the table above, the tufted carpets of the present invention exhibit stable properties such as thickness, weight, number of loops, and pile height. The tuft pullout force is high, indicating that the carpets are not prone to shedding and have good durability. Furthermore, the carpets exhibit high peel force, breaking strength, and tearing strength, meeting the requirements for automotive tufted carpet use. In particular, the tufted carpets of the present invention exhibit a high odor level. While some odor is present, the contents of toxic and hazardous substances and volatile organic compounds are extremely low, with some organic compounds not even detected in the carpets.

[0195] In Comparative Example 1, no adsorption layer was added, and the organic matter in the carpet was completely volatilized. Therefore, the toxic and harmful substances and organic matter content increased significantly, and the odor level also decreased accordingly. In Comparative Example 2, only coconut shell charcoal was added as an adsorbent to adsorb organic matter. Although the odor of the carpet was reduced, the mechanical properties of the carpet were reduced due to the weak binding force between it and the organic matter. At the same time, although the coconut shell charcoal could temporarily adsorb some organic matter, it would still release the organic matter as the temperature increased. In Comparative Example 3, the coconut shell charcoal was not acidified, which resulted in fewer surface functional groups on the coconut shell charcoal surface, which was comparable to titanium dioxide. During the interaction, less titanium dioxide is loaded, so less organic matter can be adsorbed; in Comparative Example 4, only deionized water is used as the solvent, and the hydrothermal temperature is increased, which leads to the hydrolysis of tetrabutyl titanate and the loading of titanium dioxide in the hydrothermal process. Titanium dioxide rapidly aggregates, so that its loading on the coconut shell charcoal is not uniform, resulting in the subsequent adsorption and decomposition processes being hindered, and the organic matter content of the carpet is increased; in Comparative Example 5, the grown coconut shell charcoal is not calcined, resulting in weak binding force of titanium dioxide on the coconut shell charcoal, resulting in instability during the subsequent mixing process with polyethylene, and reducing the content of organic matter that can be adsorbed.

[0196] Odor rating standards described in the present invention:

[0197] Level 1: There is an unbearable odor;

[0198] Level 2: There is a strong disturbing odor;

[0199] Level 3: There is a disturbing odor;

[0200] Level 4: There is a noticeable odor, but it is not disturbing;

[0201] Level 5: There is an odor, but it is not disturbing;

[0202] Level 6: no odor;

[0203] The toxic and hazardous substances in the present invention include lead (Pb), mercury (Hg), hexavalent chromium (Cr 6+ ), polybrominated biphenyls (PBBs), polybrominated diphenyl ethers (PBDEs);

[0204] The low-temperature impact test conditions described in the present invention are as follows: the sample is placed at 80°C for 24 hours, then at 23°C for 2 hours, and then at -40°C for 4 hours, and then impacted by a 500g drop weight with a diameter of 50mm and vertically dropped from a height of 400mm.

[0205] The test standard for the content of volatile organic compounds in the present invention is "Q / JQ 11241-2023".

[0206] Based on the above, it can be seen that the tufted carpet with composite polymer coconut shell charcoal of the present invention has a wide range of applications, low cost and great market prospects.

[0207] The above description is merely a preferred embodiment of the present invention and does not constitute any other form of limitation to the present invention. Any modification or equivalent variation based on the technical essence of the present invention shall still fall within the scope of protection claimed by the present invention.

Claims

1. A tufted carpet made of composite polymer coconut shell charcoal, characterized in that: The tufted carpet of composite polymer coconut shell charcoal has a multi-layer structure, which comprises, from bottom to top, a base layer, a reinforcement layer, an adsorption layer, an adhesive layer, a base fabric layer and a pile layer, wherein the raw materials of the adsorption layer include polyethylene powder, formaldehyde-removing crystals, a compatibilizer and coconut shell charcoal, the formaldehyde-removing crystals are loaded on the coconut shell charcoal, and then mixed with the compatibilizer and polyethylene powder and then sprinkled on the adhesive layer, and the adsorption layer is prepared at high temperature; The preparation method of the composite polymer coconut shell charcoal tufted carpet comprises the following steps: Step 1: Tufting the expanded continuous filaments onto a non-woven base fabric through a tufting machine to obtain a pile layer and a base fabric layer; and coating the bottom of the base fabric layer with water-based foamed latex, and drying the mixture to obtain an adhesive layer; Step 2, adding concentrated nitric acid to the coconut shell charcoal under low temperature stirring, gradually heating and stirring to acidify, washing the acidified coconut shell charcoal with deionized water, and drying after washing to obtain activated coconut shell charcoal; Step 3, stirring and dispersing the activated coconut shell charcoal and the formaldehyde-removing crystals in anhydrous ethanol and deionized water, reacting them in a closed hydrothermal manner after ultrasonication, cooling and filtering, and drying the solid product to obtain in-situ grown coconut shell charcoal; Step 4, calcining the in-situ grown coconut shell charcoal and then cooling it to room temperature to obtain loaded coconut shell charcoal, and uniformly mixing the loaded coconut shell charcoal with a compatibilizer and polyethylene powder to obtain organic coconut shell charcoal; Step 5: Evenly sprinkle the organic coconut shell charcoal on the back of the adhesive layer, heat it to melt and bond it to the back of the adhesive layer, and cool it to room temperature to obtain an adsorption layer. Then, laminate a polyethylene-polyamide-polyethylene composite film on the back of the adsorption layer, and cool it to room temperature to obtain a reinforcement layer. Then, laminate a polyethylene terephthalate needle-punched felt bottom layer on the back of the reinforcement layer to obtain the composite polymer coconut shell charcoal tufted carpet. The formaldehyde-removing crystal in step 3 is tetrabutyl titanate; The thickness of the composite polymer coconut shell charcoal tufted carpet is 12.4-12.9 mm, and the weight is 1910-1997 g / m 2 , the number of cut pile loops is 2550-2660 / 100cm 2 , the pile height is 4-5mm, and the tuft extraction force is 26-30N; The tufted carpet of the composite polymer coconut shell charcoal has a peeling force of 58-66N, a weft breaking strength of 1340-1410N / 5cm, a warp breaking strength of 1520-1630N / 5cm, a weft tearing strength of 210-270N, and a warp tearing strength of 210-280N. The odor level of the composite polymer coconut shell charcoal tufted carpet is 3.5-5, the content of toxic and harmful substances is ≤1000mg / kg, the content of cadmium is ≤100mg / kg, and the content of polycyclic aromatic hydrocarbons is ≤0.2mg / kg; The formaldehyde content in the volatile organic matter content of the tufted carpet of the composite high molecular coconut shell charcoal is less than 19 μg / m 3 , acetaldehyde content <48.5μg / m 3 , toluene content <5.2μg / m 3 , while acrylic acid, acetone, benzene, ethylbenzene, xylene and styrene were not detected; the total volatile organic compound content was <1170μg / m 3 .

2. A method for preparing the composite polymer coconut shell charcoal tufted carpet according to claim 1, characterized in that: The following steps are involved: Step 1: Tufting the expanded continuous filaments onto a non-woven base fabric through a tufting machine to obtain a pile layer and a base fabric layer; and coating the bottom of the base fabric layer with water-based foamed latex, and drying the mixture to obtain an adhesive layer; Step 2, adding concentrated nitric acid to the coconut shell charcoal under low temperature stirring, gradually heating and stirring to acidify, washing the acidified coconut shell charcoal with deionized water, and drying after washing to obtain activated coconut shell charcoal; Step 3, stirring and dispersing the activated coconut shell charcoal and the formaldehyde-removing crystals in anhydrous ethanol and deionized water, reacting them in a closed hydrothermal manner after ultrasonication, cooling and filtering, and drying the solid product to obtain in-situ grown coconut shell charcoal; Step 4, calcining the in-situ grown coconut shell charcoal and then cooling it to room temperature to obtain loaded coconut shell charcoal, and uniformly mixing the loaded coconut shell charcoal with a compatibilizer and polyethylene powder to obtain organic coconut shell charcoal; Step 5: Evenly sprinkle the organic coconut shell charcoal on the back of the adhesive layer, heat it to melt and bond it to the back of the adhesive layer, and obtain an adsorption layer after cooling to room temperature. Then, composite a polyethylene-polyamide-polyethylene composite film on the back of the adsorption layer, and obtain a reinforcement layer after cooling to room temperature. Composite a bottom layer of polyethylene terephthalate needle-punched felt on the back of the reinforcement layer to obtain the composite polymer coconut shell charcoal tufted carpet.

3. The preparation method according to claim 2, characterized in that The water-based foaming latex in step 1 is ethylene-vinyl acetate copolymer water-based foaming latex.

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

1.

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

6. The preparation method according to claim 2, characterized in that The temperature of the hydrothermal reaction in step 3 is 150-160° C., and the time of the hydrothermal reaction is 12-15 hours.

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

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

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