EPP material and tatami mat using the same

Abstract

The application relates to an EPP material and a tatami mat using the same, and relates to the technical field of EPP materials. The EPP material is formed by fusing EPP particles into a plate, and the surface of the plate is coated with hydrophobic antibacterial paint. The preparation raw materials of the EPP particles include the following components in mass fractions: 80-100 parts of polypropylene resin, 1-3 parts of a nucleating agent, 6-8 parts of modified graphene composite material, 5-10 parts of a flame retardant, 5-15 parts of a toughening agent and 0.5-1.5 parts of a surfactant. The preparation raw materials of the modified graphene composite material include hydrophobic modified graphene oxide, hydrophobic antibacterial nano zinc oxide and a coupling agent modified ammonium polyphosphate. The tatami mat using the EPP material includes the EPP material, a surface layer and stitches. The surface layer is fixedly connected with the EPP material through the stitches. The application has the effects of improving the flame retardant property, the waterproof property and the antibacterial property of the EPP material, and the prepared tatami mat is environmentally friendly and comfortable, and has good use experience.

Description

Technical Field

[0001] This application relates to the field of EPP material technology, and in particular to an EPP material and a tatami mat using the EPP material. Background Technology

[0002] In modern home life, tatami mats are favored by consumers for their comfort, practicality, and efficient space utilization, and are widely used in bedrooms, living rooms, and other spaces, becoming a key component of home furnishings. As people's pursuit of quality of life continues to improve, the performance requirements for tatami mat materials are becoming increasingly stringent.

[0003] EPP (expanded polypropylene beads) material, as a new type of high-performance foam material, has emerged in many fields such as packaging and automotive interiors in recent years. With its excellent physical properties, such as good cushioning, high strength, lightweight and recyclability, it has gradually attracted the attention of the home furnishing industry and provided a new direction for the innovation of tatami mat materials.

[0004] However, most tatami mats currently on the market are made of traditional materials such as sponge and coconut fiber, which have revealed many problems during use. Sponge is prone to deformation, has poor breathability, and may breed bacteria with long-term use; while coconut fiber mats have some breathability, they are not good at moisture and insect prevention, and some products use excessive glue, leading to the risk of excessive formaldehyde release, which seriously affects the health and experience of users. Therefore, it is necessary to provide an EPP material and tatami mats made using this EPP material to improve product performance and user experience. Summary of the Invention

[0005] In order to improve the performance of tatami mats, this application provides an EPP material and a tatami mat using the EPP material.

[0006] This application provides an EPP material and a tatami mat using the EPP material, employing the following technical solution:

[0007] Firstly, the EPP material provided in this application adopts the following technical solution:

[0008] An EPP material, wherein the EPP material is formed by fusing EPP particles into a sheet, and the surface of the sheet is coated with a hydrophobic and antibacterial coating, wherein the raw materials for preparing the EPP particles include the following components in parts by weight:

[0009] 80-100 parts of polypropylene resin

[0010] 1-3 parts of nucleating agent

[0011] 6-8 parts of modified graphene composite material

[0012] 5-10 parts flame retardant

[0013] 5-15 parts toughening agent

[0014] Surfactant 0.5-1.5 parts;

[0015] The raw materials for preparing the modified graphene composite material include hydrophobically modified graphene oxide, hydrophobically antibacterial nano zinc oxide, and coupling agent modified ammonium polyphosphate.

[0016] Hydrophobic modified graphene oxide in modified graphene composites, through its layered structure, can delay heat and oxygen transfer. Synergistically, modified ammonium polyphosphate, acting as a coupling agent, releases phosphate ester-based flame-retardant active substances and forms a char layer during combustion, enhancing flame-retardant performance through both gas-phase and condensed-phase mechanisms. After surface hydrophobication treatment, hydrophobic modified graphene oxide and hydrophobic antibacterial nano-zinc oxide construct a low surface energy interface within and on the material, effectively hindering water penetration. Combined with the dispersion optimization effect of surfactants on each component, a continuous hydrophobic network is formed, significantly enhancing waterproof performance. Hydrophobic and antibacterial properties are also achieved. Nano zinc oxide possesses both physical shielding and chemical antibacterial functions. Its loaded antibacterial components can disrupt bacterial cell membranes through contact or slow-release action, inhibiting microbial attachment and reproduction. Combined with a hydrophobic antibacterial coating on the surface, it constructs a dual antibacterial system of internal reinforcement and surface protection, achieving long-term inhibition of bacteria such as Escherichia coli and Staphylococcus aureus. The above components, together with polypropylene resin, nucleating agents, flame retardants, toughening agents, and surfactants, regulate the performance of EPP materials, improving their flame retardant, waterproof, and antibacterial properties, thus meeting the application requirements for multifunctional lightweight materials.

[0017] Preferably, the raw materials for preparing the hydrophobically modified graphene oxide include graphene oxide, hydrazine hydrate, and octadecylamine.

[0018] Hydrazine hydrate acts as a reducing agent, removing hydrophilic groups such as epoxy and hydroxyl groups from the surface of graphene oxide and restoring some of the conjugated structure to enhance thermal conductivity and mechanical properties. Octadecylamine is grafted onto the surface of graphene oxide sheets through an amidation reaction, and its long-chain alkyl groups form a hydrophobic barrier, changing the hydrophilicity of graphene oxide to hydrophobicity and improving its dispersibility and compatibility in the non-polar matrix of polypropylene. The modified graphene oxide in EPP materials can slow down the rate of heat and oxygen transfer during combustion due to the physical barrier effect of the sheet structure. At the same time, it forms a sheet-carbon layer composite flame retardant system with the coupling agent modified ammonium polyphosphate, improving the flame retardant efficiency of the condensed phase. Its hydrophobic surface, together with the hydrophobic antibacterial nano zinc oxide inside the material and the hydrophobic antibacterial coating on the surface, constructs a continuous low surface energy network from the inside to the surface, effectively inhibiting water penetration. The uniformly dispersed graphene oxide enhances the intermolecular forces of polymers through π-π conjugation, indirectly improving the overall strength and weather resistance of the material, thereby improving the flame retardant and waterproof performance of EPP materials.

[0019] Preferably, the mass ratio of graphene oxide, hydrazine hydrate and octadecylamine is 1:0.02:(0.25-0.35).

[0020] The hydrophobically modified graphene oxide prepared according to the above mass ratio has good flame retardant and hydrophobic properties.

[0021] Preferably, the raw materials for preparing the hydrophobic antibacterial nano zinc oxide include nano zinc oxide, silver nitrate, and isopropyltrioleoyl oxytitanate.

[0022] Silver nitrate, after reduction, forms silver nanoparticles loaded on the surface of zinc oxide nanoparticles. The slow-release effect of silver ions disrupts the permeability of bacterial cell membranes, synergistically enhancing the antibacterial performance with the antibacterial effect of zinc oxide itself. Isopropyl trioleoyl oxytitanate undergoes hydrophobic modification, forming a hydrophobic coating layer on the zinc oxide nanoparticle surface through its amphiphilic structure of long-chain alkyl groups and polar groups. This improves its dispersibility in the non-polar polypropylene matrix and reduces nanoparticle aggregation. The hydrophobic antibacterial zinc oxide nanoparticles in EPP materials achieve long-lasting antibacterial effects through a silver-zinc composite antibacterial system, inhibiting the attachment and reproduction of microorganisms inside and on the surface of the material. Its hydrophobic surface, together with the hydrophobically modified graphene oxide and the surface-coated hydrophobic antibacterial coating, forms a low surface energy network, hindering water penetration and cutting off the moist environment for bacterial growth, while simultaneously improving the material's water resistance. Furthermore, the uniformly dispersed zinc oxide nanoparticles act as a physical barrier to delay heat transfer, synergistically enhancing the flame retardant properties of the material with the coupling agent-modified ammonium polyphosphate, thereby improving the antibacterial and waterproof properties of the EPP material.

[0023] Preferably, the mass ratio of the nano zinc oxide, silver nitrate and isopropyl trioleoyl oxytitanate is 1:0.15:(0.03-0.05).

[0024] The hydrophobic antibacterial nano zinc oxide prepared according to the above mass ratio has good waterproof and antibacterial properties.

[0025] Preferably, the toughening agent comprises ethylene-octene copolymer and ethylene propylene diene monomer (EPDM) rubber.

[0026] Ethylene-octene copolymer, as a polyolefin elastomer, exhibits excellent compatibility with the polypropylene matrix. Its flexible segments form island structures within the matrix. When the material is subjected to external impact, the elastic phase deforms to absorb energy and induces crazes and shear bands in the matrix, delaying crack propagation. Ethylene propylene diene monomer (EPDM), as the rubber phase, possesses unsaturated double bond structures that impart excellent weather resistance to the material. Furthermore, the rubber particles dispersed within the polypropylene matrix act as stress concentration points, promoting the dissipation of impact energy at the multiphase interface and effectively improving elongation at break. When the two are compounded, the ethylene-octene copolymer enhances its interfacial bonding with polypropylene through intermolecular forces, while EPDM optimizes phase distribution through physical crosslinking effects, forming a dual toughening network of elastomer and rubber. This significantly improves resilience while maintaining the lightweight characteristics of EPP. Simultaneously, the toughening agent can regulate the melt viscosity of polypropylene, promoting uniform nucleation and stable growth of cells during foaming, preventing cell collapse or merging, thereby synergistically enhancing the overall mechanical properties and processing stability of EPP materials.

[0027] Preferably, the raw materials for preparing the hydrophobic antibacterial coating include 40-50 parts of organosilicon modified polyurethane resin, 2-3 parts of quaternary ammonium salt antibacterial agent, 4-6 parts of hydrophobic nano titanium dioxide, 3-5 parts of film-forming aid, 0.03-0.05 parts of dispersant, 0.5-1 parts of leveling agent, and 0.3-0.5 parts of defoamer.

[0028] Organosilicon-modified polyurethane resin serves as the main film-forming agent. The siloxane groups in its molecular chain are oriented on the coating surface, forming a low surface energy interface that effectively blocks water penetration while giving the coating excellent flexibility and adhesion. Quaternary ammonium salt antibacterial agents disrupt cell membrane integrity and inhibit microbial reproduction through electrostatic interactions between cationic active groups and bacterial cell membranes, thus enhancing antibacterial performance. Hydrophobic nano-titanium dioxide is uniformly dispersed in the coating. Its nano-sized particles enhance hydrophobicity through the synergistic effect of rough surface and low surface energy, and can also act as a physical barrier to prevent bacterial adhesion, forming a chemical-physical dual antibacterial mechanism with the quaternary ammonium salt antibacterial agents. Film-forming aids lower the minimum film-forming temperature of the resin, ensuring complete coating formation at room temperature. The combined use of dispersants, leveling agents, and defoamers ensures uniform dispersion of nanoparticles and a smooth coating surface, avoiding defects such as agglomeration and pinholes. The components work together synergistically to form an integrated coating on the EPP board surface that combines hydrophobic protection and long-lasting antibacterial function, effectively improving the material's waterproof and antibacterial properties.

[0029] Preferably, the EPP material is prepared using the following steps:

[0030] Polypropylene resin, nucleating agent, modified graphene composite material, flame retardant, toughening agent and surfactant are mixed, stirred and melt-blended and extruded to obtain pretreated granules; carbon dioxide is added to the pretreated granules, sealed and heated and pressurized to fully impregnate the granules with carbon dioxide, and then depressurized to atmospheric pressure to foam, thus obtaining EPP granules; the EPP granules are evenly spread in a mold and hot-pressed to obtain EPP sheets; a hydrophobic antibacterial coating is coated on the surface of the EPP sheets, and then heated and dried to obtain EPP material.

[0031] The EPP material prepared according to the above steps has good flame retardant, waterproof and antibacterial properties, meeting the application requirements for multifunctional lightweight materials.

[0032] Secondly, this application provides a tatami mat made of EPP material, using the following technical solution:

[0033] A tatami mat using EPP material includes EPP material, a surface layer, and stitching; the EPP material is in the shape of a rectangular plate; the surface layer covers one side and four sidewalls of the EPP material, and the surface layer is fixedly connected to the EPP material by stitching.

[0034] EPP material is lightweight and high-strength, making tatami mats both portable and resilient, meeting the needs of frequent movement and multiple people stepping on them in daily use. The surface layer is covered with EPP, and the flexible fabric enhances the comfort and aesthetics of the surface, forming a physical barrier to protect the EPP material from direct erosion by dust and stains. Combined with the hydrophobic and antibacterial properties of EPP material itself, it effectively reduces mold growth and bacterial adhesion. The stitching securely connects the surface layer and the EPP material, not only preventing displacement due to long-term use, but also dispersing local stress through reasonable stitch spacing and stitch design, enhancing the overall structural durability, forming a multifunctional tatami mat product that combines lightweight, comfort, safety, and durability.

[0035] Preferably, the material of the surface layer includes one of the following: straw weaving, PP weaving, modified paper weaving, fabric weaving, and rattan weaving.

[0036] Using the above-mentioned surface material can provide tatami mats with good aesthetics and comfort.

[0037] In summary, this application includes at least one of the following beneficial technical effects:

[0038] 1. Hydrophobically modified graphene oxide in the modified graphene composite material, due to the barrier effect of its layered structure, can delay heat and oxygen transfer. It works synergistically with the coupling agent-modified ammonium polyphosphate to release phosphate ester flame-retardant active substances and form a char layer during combustion, thus improving flame-retardant performance through both gas-phase and condensed-phase mechanisms. After surface hydrophobication treatment, hydrophobically modified graphene oxide and hydrophobically antibacterial nano-zinc oxide construct a low surface energy interface within and on the surface of the material, effectively hindering water penetration. Combined with the dispersion optimization effect of surfactants on each component, a continuous hydrophobic network is formed, significantly enhancing waterproof performance. The hydrophobic and antibacterial properties further enhance the flame retardant performance. The nano-zinc oxide possesses both physical shielding and chemical antibacterial functions. Its loaded antibacterial components can disrupt bacterial cell membranes through contact or slow-release action, inhibiting microbial attachment and reproduction. Combined with a hydrophobic antibacterial coating on the surface, it constructs a dual antibacterial system of internal reinforcement and surface protection, achieving long-term inhibition of bacteria such as Escherichia coli and Staphylococcus aureus. The above components, together with polypropylene resin, nucleating agents, flame retardants, toughening agents, and surfactants, regulate the performance of EPP materials, improving their flame retardant, waterproof, and antibacterial properties, thus meeting the application requirements for multifunctional lightweight materials.

[0039] 2. Hydrazine hydrate acts as a reducing agent, removing hydrophilic groups such as epoxy and hydroxyl groups from the surface of graphene oxide and restoring some of the conjugated structure to enhance thermal conductivity and mechanical properties. Octadecylamine is grafted onto the surface of graphene oxide sheets through an amidation reaction, and its long-chain alkyl groups form a hydrophobic barrier, changing the hydrophilicity of graphene oxide to hydrophobicity, thus improving its dispersibility and compatibility in the non-polar matrix of polypropylene. The modified graphene oxide in EPP materials can slow down the rate of heat and oxygen transfer during combustion due to the physical barrier effect of the sheet structure. At the same time, it forms a sheet-carbon composite flame retardant system with the coupling agent modified ammonium polyphosphate, improving the flame retardant efficiency of the condensed phase. Its hydrophobic surface, together with the hydrophobic antibacterial nano zinc oxide inside the material and the hydrophobic antibacterial coating on the surface, synergistically constructs a continuous low surface energy network from the inside to the surface, effectively inhibiting water penetration. The uniformly dispersed graphene oxide enhances the intermolecular forces of polymers through π-π conjugation, indirectly improving the overall strength and weather resistance of the material, thereby improving the flame retardant and waterproof properties of EPP materials.

[0040] 3. Silver nitrate, after reduction, forms silver nanoparticles that are loaded onto the surface of zinc oxide nanoparticles. The slow-release effect of silver ions disrupts the permeability of bacterial cell membranes, synergistically enhancing the antibacterial performance with the metal ion antibacterial effect of zinc oxide itself. Isopropyl trioleoyl oxytitanate undergoes hydrophobic modification, forming a hydrophobic coating layer on the surface of the zinc oxide nanoparticles through its amphiphilic structure of long-chain alkyl groups and polar groups. This improves its dispersibility in the non-polar polypropylene matrix and reduces nanoparticle aggregation. The hydrophobic antibacterial zinc oxide nanoparticles in EPP materials are enhanced by silver... - The zinc composite antibacterial system achieves long-lasting antibacterial effects, inhibiting the attachment and reproduction of microorganisms inside and on the surface of the material. Its hydrophobic surface, together with the hydrophobic modified graphene oxide in the material and the hydrophobic antibacterial coating on the surface, forms a low surface energy network, which hinders water penetration, cuts off the humid environment for bacterial growth, and improves the water resistance of the material. In addition, the uniformly dispersed nano zinc oxide particles can act as a physical barrier to delay heat transfer and synergistically enhance the flame retardant properties of the material with the coupling agent modified ammonium polyphosphate, thereby improving the antibacterial and waterproof properties of the EPP material. Attached Figure Description

[0041] Figure 1 This is a cross-sectional structural diagram of a tatami mat using EPP material, as described in Application Example 1 of this application.

[0042] Figure 2 This is a cross-sectional structural diagram of a tatami mat made of EPP material, as shown in Application Example 2 of this application.

[0043] Figure 3 This is a cross-sectional structural diagram of a tatami mat made of EPP material, as shown in Application Example 3 of this application.

[0044] Figure 4 This is a cross-sectional structural diagram of a tatami mat made of EPP material, as shown in Application Example 5 of this application.

[0045] Explanation of reference numerals in the attached drawings: 1. EPP material; 11. First EPP sheet; 12. Second EPP sheet; 2. Surface layer; 3. Seam; 4. Side edging layer; 5. Padding layer. Detailed Implementation

[0046] This application discloses an EPP material and a tatami mat using the EPP material. Unless otherwise specified, all raw materials used in this application are commercially available. The following detailed description, in conjunction with embodiments, comparative examples, and application examples, further illustrates this application:

[0047] Raw material specifications: Graphene oxide was purchased from Beijing Deco Island Gold Technology Co., Ltd.; hydrazine hydrate (CAS No.: 7803-57-8); octadecylamine (CAS No.: 124-30-1); nano zinc oxide (CAS No.: 1314-13-2) with a particle size of 50 nm; silver nitrate (CAS No.: 7761-88-8); sodium borohydride (CAS No.: 16940-66-2); isopropyltrioleoyl titanate (CAS No.: 16940-66-2). The following ingredients were found to be unrelated to the main text: Ammonium polyphosphate (CAS No.: 61417-49-0), molecular weight 10000, γ-aminopropyltriethoxysilane (CAS No.: 57022-99-0), polyvinyl alcohol (CAS No.: 9002-89-5), hydrophobic nano-titanium dioxide (CAS No.: 13463-67-7), particle size 30nm, and sodium polyacrylate (CAS No.: 9003-04-7) as dispersant. The silicone-modified polyurethane resin was purchased from Fenyangtang. The film-forming aid was alcohol ester-12 (CAS No.: 6846-50-0), the quaternary ammonium salt antibacterial agent was dodecyl dimethyl benzyl ammonium chloride (CAS No.: 139-07-1), the leveling agent was polydimethylsiloxane (CAS No.: 9006-65-9), the defoamer was Dow Corning DC-57, and the polypropylene resin was (CAS No.: 9003-07-0). The melt flow rate was 30 g / L. The nucleating agent is talc powder with a particle size of 3μm. The flame retardant is melamine cyanurate (CAS No.: 37640-57-6). The toughening agent is composed of ethylene-octene copolymer and EPDM rubber in a mass ratio of 1:1. The surfactant is sodium dodecyl sulfate (CAS No.: 151-21-3). The foaming ratio of EPP material is 10-35 times, the thickness is 2-6cm, the surface material is PP woven fabric, and the stitching is high-strength stitching.

[0048] Example 1

[0049] Preparation of modified graphene composite materials

[0050] 7.87 g of graphene oxide was dispersed in 100 mL of deionized water, 0.16 g of hydrazine hydrate was added, and the mixture was stirred at 200 rpm for 1 h at 60 °C. After centrifugation and washing with deionized water, the mixture was dispersed in 150 mL of ethanol, 1.97 g of octadecylamine was added, and the mixture was refluxed at 70 °C for 2 h. After filtration, the mixture was dried at 60 °C to obtain hydrophobically modified graphene oxide.

[0051] 8.47 g of nano zinc oxide was dispersed in 60 mL of deionized water, 1.27 g of silver nitrate was added, and the mixture was sonicated for 30 min. Then, 10 mL of 1 mol / L sodium borohydride aqueous solution was added dropwise, and the mixture was stirred at 200 rpm for 30 min. After centrifugation and washing with deionized water, modified nano zinc oxide was obtained. The modified nano zinc oxide and 0.26 g of isopropyltrioleyl oxytitanate were dispersed in 100 mL of ethanol, and the mixture was stirred at 200 rpm for 2 h at 70 °C. After centrifugation, the mixture was vacuum dried at 40 °C to obtain hydrophobic and antibacterial nano zinc oxide.

[0052] Ammonium polyphosphate was vacuum dried at 60℃ for 4 h to obtain anhydrous ammonium polyphosphate; 2 g of γ-aminopropyltriethoxysilane was dissolved in 100 mL of anhydrous ethanol, and glacial acetic acid was added dropwise to adjust the pH to 4.5. The mixture was stirred in a water bath at 60℃ for 30 min to obtain a silanol solution; 11.53 g of anhydrous ammonium polyphosphate was added to the silanol solution, and the mixture was stirred at 200 rpm at 60℃ for 1 h. After the reaction was completed, the mixture was centrifuged, washed with anhydrous ethanol, and vacuum dried at 80℃ to obtain coupling agent modified ammonium polyphosphate.

[0053] 2.31 g of hydrophobic modified graphene oxide, 5.76 g of hydrophobic antibacterial nano zinc oxide, 11.53 g of coupling agent modified ammonium polyphosphate, and 0.4 g of polyvinyl alcohol were dispersed in 100 mL of deionized water and stirred at 200 rpm for 30 min. After sonication for 60 min, a mixture was obtained. The mixture was then spray-dried with the inlet temperature controlled at 190 °C, the outlet temperature at 90 °C, the atomizing disc speed at 10000 rpm, the feed rate at 5 mL / min, and the atomized droplet size at 50 μm to obtain the modified graphene composite filler.

[0054] Preparation of hydrophobic antibacterial coatings

[0055] 4g of hydrophobic nano-titanium dioxide and 0.03g of dispersant were dispersed in 20g of deionized water and sonicated for 30min. The mixture was then stirred at 1500rpm for 10min. 40g of silicone-modified polyurethane resin and 3g of film-forming aid were added and stirred at 800rpm for 30min. 2g of quaternary ammonium salt antibacterial agent was added and stirred at 500rpm for 15min. 0.5g of leveling agent and 0.3g of defoamer were added and stirred at 300rpm for 10min. The viscosity was adjusted to 4000mPa·s using deionized water. Impurities were removed by filtering through a 100-mesh filter to obtain the hydrophobic antibacterial coating.

[0056] Preparation of EPP materials

[0057] 80g of polypropylene resin, 1g of nucleating agent, 6g of modified graphene composite material, 5g of flame retardant, 5g of toughening agent, and 0.5g of surfactant were mixed and stirred at 200 rpm for 15 minutes. The mixture was then melt-blended and extruded into granules using a twin-screw extruder at a temperature of 200-220℃ and a screw speed of 200 rpm to obtain pretreated granules. The pretreated granules were then placed in a high-pressure foaming kettle, carbon dioxide was added, and the kettle was sealed and heated to 140℃. The pressure was maintained at 2.5 MPa for 15 minutes to allow the carbon dioxide to fully impregnate the granules. Subsequently, the pressure was rapidly released to atmospheric pressure for foaming to obtain EPP granules. The EPP granules were evenly spread in a mold and fused into a sheet using a hot-pressing welding device at a temperature of 165℃, a pressure of 0.8 MPa, and a time of 6 minutes to obtain an EPP sheet. A hydrophobic antibacterial coating was coated on the surface of the EPP sheet and cured by drying at 80℃ for 2 hours to obtain the EPP material.

[0058] Example 2

[0059] Preparation of modified graphene composite materials

[0060] 7.3 g of graphene oxide was dispersed in 100 mL of deionized water, 0.15 g of hydrazine hydrate was added, and the mixture was stirred at 200 rpm for 1 h at 60 °C. After centrifugation and washing with deionized water, the mixture was dispersed in 150 mL of ethanol, 2.55 g of octadecylamine was added, and the mixture was refluxed at 70 °C for 2 h. After filtration, the mixture was dried at 60 °C to obtain hydrophobically modified graphene oxide.

[0061] 8.33 g of nano zinc oxide was dispersed in 60 mL of deionized water, 1.25 g of silver nitrate was added, and the mixture was sonicated for 30 min. Then, 10 mL of 1 mol / L sodium borohydride aqueous solution was added dropwise, and the mixture was stirred at 200 rpm for 30 min. After centrifugation and washing with deionized water, modified nano zinc oxide was obtained. The modified nano zinc oxide and 0.42 g of isopropyltrioleyl oxytitanate were dispersed in 100 mL of ethanol, and the mixture was stirred at 200 rpm for 2 h at 70 °C. After centrifugation, the mixture was vacuum dried at 40 °C to obtain hydrophobic and antibacterial nano zinc oxide.

[0062] Ammonium polyphosphate was vacuum dried at 60℃ for 4 h to obtain anhydrous ammonium polyphosphate; 2 g of γ-aminopropyltriethoxysilane was dissolved in 100 mL of anhydrous ethanol, and glacial acetic acid was added dropwise to adjust the pH to 4.5. The mixture was stirred in a water bath at 60℃ for 30 min to obtain a silanol solution; 11.53 g of anhydrous ammonium polyphosphate was added to the silanol solution, and the mixture was stirred at 200 rpm at 60℃ for 1 h. After the reaction was completed, the mixture was centrifuged, washed with anhydrous ethanol, and vacuum dried at 80℃ to obtain coupling agent modified ammonium polyphosphate.

[0063] 2.31 g of hydrophobic modified graphene oxide, 5.76 g of hydrophobic antibacterial nano zinc oxide, 11.53 g of coupling agent modified ammonium polyphosphate, and 0.4 g of polyvinyl alcohol were dispersed in 100 mL of deionized water and stirred at 200 rpm for 30 min. After sonication for 60 min, a mixture was obtained. The mixture was then spray-dried with the inlet temperature controlled at 190 °C, the outlet temperature at 90 °C, the atomizing disc speed at 10000 rpm, the feed rate at 5 mL / min, and the atomized droplet size at 50 μm to obtain the modified graphene composite filler.

[0064] Preparation of hydrophobic antibacterial coatings

[0065] Disperse 6g of hydrophobic nano-titanium dioxide and 0.05g of dispersant into 20g of deionized water, sonicate for 30min, stir at 1500rpm for 10min, add 50g of silicone-modified polyurethane resin and 5g of film-forming aid, stir at 800rpm for 30min, add 3g of quaternary ammonium salt antibacterial agent, stir at 500rpm for 15min, add 1g of leveling agent and 0.5g of defoamer, stir at 300rpm for 10min, adjust the viscosity to 4000mPa·s with deionized water, filter through a 100-mesh filter to remove impurities, and obtain the hydrophobic antibacterial coating.

[0066] Preparation of EPP materials

[0067] 100g of polypropylene resin, 3g of nucleating agent, 8g of modified graphene composite material, 10g of flame retardant, 15g of toughening agent, and 1.5g of surfactant were mixed and stirred at 200 rpm for 15 minutes. The mixture was then melt-blended and extruded into granules using a twin-screw extruder at a temperature of 200-220℃ and a screw speed of 200 rpm to obtain pretreated granules. The pretreated granules were then placed in a high-pressure foaming kettle, carbon dioxide was added, and the kettle was sealed and heated to 140℃. The pressure was maintained at 2.5 MPa for 15 minutes to allow the carbon dioxide to fully impregnate the granules. Subsequently, the pressure was rapidly released to atmospheric pressure for foaming to obtain EPP granules. The EPP granules were evenly spread in a mold and fused into a sheet using a hot-pressing welding device at a temperature of 165℃, a pressure of 0.8 MPa, and a time of 6 minutes to obtain an EPP sheet. A hydrophobic antibacterial coating was coated on the surface of the EPP sheet and cured by drying at 80℃ for 2 hours to obtain the EPP material.

[0068] Example 3

[0069] Preparation of modified graphene composite materials

[0070] 7.58 g of graphene oxide was dispersed in 100 mL of deionized water, 0.15 g of hydrazine hydrate was added, and the mixture was stirred at 200 rpm for 1 h at 60 °C. After centrifugation and washing with deionized water, the mixture was dispersed in 150 mL of ethanol, 2.27 g of octadecylamine was added, and the mixture was refluxed at 70 °C for 2 h. After filtration, the mixture was dried at 60 °C to obtain hydrophobically modified graphene oxide.

[0071] 8.4 g of nano zinc oxide was dispersed in 60 mL of deionized water, 1.26 g of silver nitrate was added, and the mixture was sonicated for 30 min. Then, 10 mL of 1 mol / L sodium borohydride aqueous solution was added dropwise, and the mixture was stirred at 200 rpm for 30 min. After centrifugation and washing with deionized water, modified nano zinc oxide was obtained. The modified nano zinc oxide and 0.34 g of isopropyltrioleyl oxytitanate were dispersed in 100 mL of ethanol, and the mixture was stirred at 200 rpm for 2 h at 70 °C. After centrifugation, the mixture was vacuum dried at 40 °C to obtain hydrophobic and antibacterial nano zinc oxide.

[0072] Ammonium polyphosphate was vacuum dried at 60℃ for 4 h to obtain anhydrous ammonium polyphosphate; 2 g of γ-aminopropyltriethoxysilane was dissolved in 100 mL of anhydrous ethanol, and glacial acetic acid was added dropwise to adjust the pH to 4.5. The mixture was stirred in a water bath at 60℃ for 30 min to obtain a silanol solution; 11.53 g of anhydrous ammonium polyphosphate was added to the silanol solution, and the mixture was stirred at 200 rpm at 60℃ for 1 h. After the reaction was completed, the mixture was centrifuged, washed with anhydrous ethanol, and vacuum dried at 80℃ to obtain coupling agent modified ammonium polyphosphate.

[0073] 2.31 g of hydrophobic modified graphene oxide, 5.76 g of hydrophobic antibacterial nano zinc oxide, 11.53 g of coupling agent modified ammonium polyphosphate, and 0.4 g of polyvinyl alcohol were dispersed in 100 mL of deionized water and stirred at 200 rpm for 30 min. After sonication for 60 min, a mixture was obtained. The mixture was then spray-dried with the inlet temperature controlled at 190 °C, the outlet temperature at 90 °C, the atomizing disc speed at 10000 rpm, the feed rate at 5 mL / min, and the atomized droplet size at 50 μm to obtain the modified graphene composite filler.

[0074] Preparation of hydrophobic antibacterial coatings

[0075] 5g of hydrophobic nano-titanium dioxide and 0.04g of dispersant were dispersed in 20g of deionized water and sonicated for 30min. The mixture was then stirred at 1500rpm for 10min. 45g of silicone-modified polyurethane resin and 4g of film-forming aid were added and stirred at 800rpm for 30min. 2.5g of quaternary ammonium salt antibacterial agent was added and stirred at 500rpm for 15min. 0.75g of leveling agent and 0.4g of defoamer were added and stirred at 300rpm for 10min. The viscosity was adjusted to 4000mPa·s using deionized water. Impurities were removed by filtering through a 100-mesh filter to obtain the hydrophobic antibacterial coating.

[0076] Preparation of EPP materials

[0077] 90g of polypropylene resin, 2g of nucleating agent, 7g of modified graphene composite material, 7.5g of flame retardant, 10g of toughening agent, and 1g of surfactant were mixed and stirred at 200 rpm for 15 min. The mixture was then melt-blended and extruded into granules using a twin-screw extruder at a temperature of 200-220℃ and a screw speed of 200 rpm to obtain pretreated granules. The pretreated granules were then placed in a high-pressure foaming kettle, carbon dioxide was added, and the kettle was sealed and heated to 140℃. The pressure was maintained at 2.5 MPa for 15 min to allow the carbon dioxide to fully impregnate the granules. Subsequently, the pressure was rapidly released to atmospheric pressure for foaming to obtain EPP granules. The EPP granules were evenly spread in a mold and fused into a sheet using a hot-pressing welding device at a temperature of 165℃, a pressure of 0.8 MPa, and a time of 6 min to obtain an EPP sheet. A hydrophobic antibacterial coating was coated on the surface of the EPP sheet and cured by drying at 80℃ for 2 h to obtain the EPP material.

[0078] Example 4

[0079] Example 4 is based on Example 3. The only difference between Example 4 and Example 3 is that the amount of graphene oxide used in Example 4 is 8.55g, the amount of hydrazine hydrate is 0.17g, and the amount of octadecylamine is 1.28g.

[0080] Example 5

[0081] Example 5 is based on Example 3. The only difference between Example 5 and Example 3 is that the amount of graphene oxide used in Example 5 is 6.8g, the amount of hydrazine hydrate is 0.14g, and the amount of octadecylamine is 3.06g.

[0082] Example 6

[0083] Example 6 is based on Example 3. The only difference between Example 6 and Example 3 is that hydrazine hydrate is not added when preparing the modified graphene composite material in Example 6.

[0084] Example 7

[0085] Example 7 is based on Example 3. The only difference between Example 7 and Example 3 is that in Example 7, the amount of nano zinc oxide is 8.62g, the amount of silver nitrate is 1.29g, and the amount of isopropyltrioleoyloxytitanate is 0.09g.

[0086] Example 8

[0087] Example 8 is based on Example 3. The only difference between Example 8 and Example 3 is that in Example 8, the amount of nano zinc oxide is 8g, the amount of silver nitrate is 1.2g, and the amount of isopropyltrioleoyloxytitanate is 0.8g.

[0088] Example 9

[0089] Example 9 is based on Example 3. The only difference between Example 9 and Example 3 is that silver nitrate is not added when preparing hydrophobic antibacterial nano-silver oxide in Example 9.

[0090] Comparative Example 1

[0091] Comparative Example 1 is based on Example 3. The only difference between Comparative Example 1 and Example 3 is that the hydrophobic modified graphene oxide is replaced with graphene oxide in Comparative Example 1.

[0092] Comparative Example 2

[0093] Comparative Example 2 is based on Example 3. The only difference between Comparative Example 2 and Example 3 is that the hydrophobic antibacterial nano zinc oxide is replaced with nano zinc oxide in Comparative Example 2.

[0094] The EPP material prepared in Example 3 was used to prepare tatami mats.

[0095] Application Example 1

[0096] Reference Figure 1 A tatami mat using EPP material 1 includes EPP material 1, surface layer 2, and seam 3; EPP material 1 is a rectangular plate-shaped integral structure, surface layer 2 covers one side and four side walls of EPP material 1, surface layer 2 and EPP material 1 are fixedly connected by seam 3, and seam 3 is evenly distributed around the side wall of EPP material 1 that is covered.

[0097] Application Example 2

[0098] Reference Figure 2 The difference between Application Example 2 and Application Example 1 is that it also includes a side edge layer 4. The side edge layer 4 is located outside the surface layer 2 and covers the four side walls of the EPP material 1. The side edge layer 4 is made of wear-resistant fabric. The surface layer 2, the side edge layer 4 and the EPP material 1 are fixedly connected by stitches 3. The stitches are evenly distributed around the side walls of the EPP material 1 that are covered.

[0099] Application Example 3

[0100] Reference Figure 3 The difference between Application Example 3 and Application Example 2 is that it also includes a padding layer 5. The padding layer 5 is located on the side of EPP material 1 that is not covered by the surface layer and is attached to the surface of EPP material. After the padding layer 5 and EPP material 1 are combined, they are covered by the surface layer 2 and the side edge layer 4. The surface layer 2, the side edge layer 4, the padding layer 5 and EPP material 1 are fixedly connected by stitches 3. The stitches are evenly distributed around the side wall of EPP material 1 that is covered.

[0101] Application Example 4

[0102] Application Example 4 is based on Application Example 3. The only difference between Application Example 4 and Application Example 3 is that the pad 5 in Application Example 4 is made of anti-slip material, which can effectively prevent the tatami mat from sliding due to the movement of the human body by increasing the coefficient of friction with the contact surface, thereby reducing the risk of accidental slipping or loss of balance in sitting posture.

[0103] Application Example 5

[0104] Reference Figure 4 The difference between Application Example 5 and Application Example 3 is that in Application Example 5, EPP material 1 is a rectangular plate-shaped layered support structure, and two types of EPP boards with foaming ratios are used: a first EPP board 11 with a foaming ratio of 25 times, a second EPP board 12 with a foaming ratio of 10 times, and a first EPP board 11 with a foaming ratio of 25 times.

[0105] Performance testing

[0106] EPP material performance testing

[0107] (1) The oxygen index of the samples prepared in the examples and comparative examples was tested using GB / T 2406.2-2009 Determination of combustion behavior of plastics by oxygen index method - Part 2: Room temperature test as the standard. Five samples were tested for each sample, and the average value was taken after measurement. The results are recorded in Table 1.

[0108] (2) Select GB / T 1034-2008 Determination of water absorption of plastics as the standard. Soak the samples prepared in the examples and comparative examples in distilled water for 24 hours and test and calculate the water absorption rate of the samples. Water absorption rate (%) = (mass after soaking - mass before soaking) / mass before soaking × 100%. The results are recorded in Table 1.

[0109] (3) The standard GB / T 31402-2015 Test Method for Antibacterial Properties of Plastic Surfaces was selected. The antibacterial rate of the samples prepared in the examples and comparative examples against Escherichia coli, Staphylococcus aureus and Candida albicans was tested. The results are recorded in Table 1.

[0110] Table 1. Test results of flame retardant, waterproof, and antibacterial properties of EPP materials.

[0111]

[0112] As shown in Table 1, the oxygen index of Examples 1-3 is greater than 31.7%, the water absorption rate is less than 0.5%, the antibacterial rate of Escherichia coli is greater than 99.5%, the antibacterial rate of Staphylococcus aureus is greater than 99.2%, and the antibacterial rate of Candida albicans is greater than 98.8%. This shows that the EPP material prepared in this application has good flame retardant, waterproof and antibacterial properties.

[0113] As shown in Table 1, the differences between Examples 4, 5, and 6 and Example 3 are only as follows: In Example 4, the mass ratio of graphene oxide, hydrazine hydrate, and octadecylamine is 1:0.02:0.15; in Example 5, the mass ratio of graphene oxide, hydrazine hydrate, and octadecylamine is 1:0.02:0.45; and in Example 6, hydrazine hydrate is not added when preparing the modified graphene composite material. Compared with Example 3, the performance of Examples 4, 5, and 6 is somewhat reduced. This is because the ratio range is disrupted, and the deviation in dosage leads to a decrease in dispersibility, a decrease in flame retardant efficiency, and an impact on hydrophobic properties. Without the addition of hydrazine hydrate, graphene oxide is not reduced, the conjugated structure is reduced, the flame retardant performance is significantly reduced, and the synergistic effect between components is also affected.

[0114] As shown in Table 1, the differences between Examples 7, 8, and 9 and Example 3 are only as follows: In Example 7, the mass ratio of nano zinc oxide, silver nitrate, and isopropyltrioleyloxytitanate is 1:0.15:0.01; in Example 8, the mass ratio of nano zinc oxide, silver nitrate, and isopropyltrioleyloxytitanate is 1:0.15:0.1; and in Example 9, silver nitrate is not added when preparing hydrophobic antibacterial nano silver oxide. Compared with Example 3, the performance of Examples 7, 8, and 9 is somewhat reduced. This is because the optimal ratio is disrupted, affecting the synergistic effect between components, and thus the waterproof and antibacterial properties are affected. The absence of nano silver oxide will affect the antibacterial synergy between components, resulting in a significant decrease in antibacterial performance.

[0115] As shown in Table 1, the only difference between Comparative Example 1 and Example 3 is that the hydrophobically modified graphene oxide was replaced with graphene oxide in Comparative Example 1. Compared with Example 3, the performance of Comparative Example 1 is significantly reduced. This is because the lack of reduction and hydrophobic modification treatment reduces the dispersibility and compatibility of graphene oxide, weakens the synergistic effect, and reduces the performance.

[0116] As shown in Table 1, the only difference between Comparative Example 2 and Example 3 is that Comparative Example 2 replaced hydrophobic antibacterial nano zinc oxide with nano zinc oxide. Compared with Example 3, the performance of Comparative Example 2 is significantly reduced. This is because replacing hydrophobic antibacterial nano zinc oxide with nano zinc oxide results in the lack of hydrophobic treatment and silver loading, which significantly reduces the antibacterial and hydrophobic properties. The synergistic effect between components is also affected, thus resulting in a significant decrease in performance.

[0117] Tatami Mat Performance Test

[0118] The tatami mats prepared in accordance with Example 5 were tested for flame retardancy (GB / T 2406.2-2009 Determination of Combustion Behavior by Oxygen Index Method for Plastics - Part 2: Room Temperature Test), combustion products test (testing combustion products), formaldehyde content test, thermal conductivity test (GB / T 10294-2008 Determination of Steady-State Thermal Resistance and Related Properties of Insulation Materials by Protective Hot Plate Method), antibacterial performance test (Escherichia coli), resilience test (GB / T 6670-2008 Determination of Resilience Performance of Flexible Foam Polymer Materials by Falling Ball Method), and water repellency test (GB / T 24218.10-2018 Water Repellency of Textiles - Part 10: Spray Test). The results are shown in Table 2.

[0119] Table 2 Performance test results of tatami mats

[0120]

[0121] As shown in Table 2, the tatami mat prepared in this application has good flame retardant properties, waterproof properties, antibacterial properties and resilience, no formaldehyde release, good heat preservation properties, and the product is safe and comfortable.

[0122] This specific embodiment is merely an explanation of this application and is not intended to limit it. Based on the above description, those skilled in the art can make various changes and modifications without departing from the technical concept of this application. The technical scope of this application is not limited to the contents of the specification but must be determined according to the scope of the claims.

Claims

1. An EPP material characterized in that: The EPP material is prepared by melting the EPP particles into a plate, and the surface of the plate is coated with a hydrophobic antibacterial coating. The raw materials for preparing the EPP particles include the following components in mass fraction: Polypropylene resin 80-100 parts Nucleating agent 1-3 parts Modified graphene composite 6-8 parts Flame retardant 5-10 parts Toughening agent 5-15 parts Surfactant 0.5-1.5 parts The raw materials for preparing the modified graphene composite include hydrophobically modified graphene oxide, hydrophobic antibacterial nano zinc oxide, and coupling agent modified ammonium polyphosphate. The raw materials for preparing the hydrophobically modified graphene oxide include graphene oxide, hydrazine hydrate, and octadecylamine. The mass ratio of the graphene oxide, hydrazine hydrate, and octadecylamine is 1:0.02:(0.25-0.35). The raw materials for preparing the hydrophobic antibacterial nano zinc oxide include nano zinc oxide, silver nitrate, and isopropyl trioleate titanate. The mass ratio of the nano zinc oxide, silver nitrate, and isopropyl trioleate titanate is 1:0.15:(0.03-0.05).

2. An EPP material according to claim 1, characterized in that: The toughening agent includes ethylene-octene copolymer and ternary ethylene-propylene rubber.

3. The EPP material of claim 1, wherein: The raw materials for preparing the hydrophobic antibacterial coating include silicone-modified polyurethane resin 40-50 parts, quaternary ammonium salt antibacterial agent 2-3 parts, hydrophobic nano titanium dioxide 4-6 parts, film-forming aid 3-5 parts, dispersant 0.03-0.05 parts, leveling agent 0.5-1 parts, and defoaming agent 0.3-0.5 parts.

4. An EPP material according to any one of claims 1 to 3, characterized in that: The EPP material is prepared by the following steps: Mix the polypropylene resin, nucleating agent, modified graphene composite, flame retardant, toughening agent, and surfactant, stir, melt blend, and extrude and granulate to obtain pretreated particles. Add carbon dioxide to the pretreated particles, seal, heat, and pressurize to allow the carbon dioxide to fully infiltrate the particles, decompress to atmospheric pressure to foam, and obtain EPP particles. Uniformly spread the EPP particles in a mold, hot-press and fuse to obtain an EPP plate. Coat the surface of the EPP plate with a hydrophobic antibacterial coating, and heat, dry, and cure to obtain the EPP material.

5. A futon mattress employing the EPP material of claim 4, characterized by: The EPP material (1), the surface layer (2), and the stitching thread (3) are included. The EPP material (1) is in the shape of a rectangular plate. The surface layer (2) covers one side and four side walls of the EPP material (1), and the surface layer (2) is fixedly connected with the EPP material (1) through the stitching thread (3).

6. The futon mattress of claim 5 wherein: The material of the surface layer includes one of grass woven fabric, PP woven fabric, modified paper woven fabric, cloth woven fabric, and rattan woven fabric.

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