A polymer hydrolysis-resistant composite carpet and its preparation method and application

Abstract

The present invention provides a polymer hydrolysis-resistant composite carpet, its preparation method, and its application, belonging to the field of polymer carpets. This invention uses polyamide 6 as a matrix, and through hydrophobic modification of silicone resin and compatibilizer-enhanced compatibility, combined with precise temperature-controlled spinning and stretching processes, achieves a balance between fiber hydrophobicity and mechanical properties. The multi-layer composite structure design, with each layer of material synergistically performing waterproofing, bonding, and supporting functions, is combined with optimized tufting, coating, and laminating processes. The result is a carpet with excellent hydrolysis resistance, wear resistance, weather resistance, and color fastness, making it adaptable to a variety of complex environments while offering both practicality and durability.

Description

Technical Field

[0001] The present invention relates to the field of polymer carpets, and in particular to a polymer hydrolysis-resistant composite carpet and a preparation method and application thereof. Background Art

[0002] With the gradual development of modern home furnishings and automotive interiors, carpets have become a vital decorative material across various industries. Carpets are subject to constant wear and tear due to their use and require frequent cleaning, significantly shortening their lifespan. In conventional carpet production, back-coating and drying the carpet with latex are key steps in securing the pile. This latex forms a film on the carpet's back, firmly bonding the pile to the base fabric and ensuring it resists shedding and pilling during use. However, with increasingly stringent global environmental regulations and rising consumer health awareness, traditional solvent-based latex is being replaced by water-based latex due to its volatile organic compounds (VOCs), pungent odor, and potential health hazards. However, the water-based nature of water-based latex, due to its water-based dispersion medium, results in significant water resistance limitations, a key bottleneck hindering the performance improvement of carpet products.

[0003] Therefore, choosing water-resistant materials to prepare carpet materials has become the first choice. For example, patent application CN110789186A discloses a carpet with good wear resistance and waterproofness, which mainly includes a carpet body. The carpet body mainly includes a base fabric, the lower surface of the base fabric is provided with a waterproof layer formed by uniformly coating silicone, and the lower surface of the waterproof layer is bonded and fixed with a non-woven fabric layer; the upper surface of the base fabric is coated with a latex layer composed of latex, and the latex layer is bonded and fixed with a chemical fiber textile fabric layer formed by uniformly coating diatom mud; the upper surface of the chemical fiber textile fabric layer is sprayed with a waterproof diaphragm layer; the upper surface of the waterproof diaphragm layer is bonded and covered with a flexible decorative layer.

[0004] The method of adding a waterproof layer to the carpet layer structure is relatively common in the current carpet industry. However, due to the poor compatibility between the waterproof layer and other adhesive layers or functional layers, its mechanical properties are reduced, and some waterproof layer materials are not environmentally friendly, which increases the odor and environmental pollution of the carpet. Therefore, on the basis of maintaining the original wear resistance, corrosion resistance and other properties of the carpet, it has become the current development trend to simultaneously improve its hydrolysis resistance.

[0005] In summary, carpets inevitably require cleaning during use. However, to meet environmental requirements for tufted carpets, traditional latex must be replaced with a less odorous water-based latex, significantly reducing the water resistance of tufted carpets. Consequently, tufted carpets have poor hydrolysis resistance, and their mechanical properties, corrosion resistance, and stability remain pressing challenges. Summary of the Invention

[0006] In response to the above problems, the present invention provides a polymer hydrolysis-resistant composite carpet, its preparation method and application. By preparing hydrolysis-resistant hydrophobic fiber bundles, tufting the hydrophobic fiber bundles into a hydrophobic pile layer, and then coating a hydrophobic latex to form an adhesive layer, the hydrolysis resistance and mechanical properties of the carpet are synergistically improved.

[0007] The present invention provides a polymer hydrolysis-resistant composite carpet. The polymer hydrolysis-resistant composite carpet comprises, from bottom to top, a bottom layer, a second support layer, a reinforcement layer, a first support layer, an adhesive layer, a base fabric layer, and a hydrophobic pile layer. The hydrophobic pile layer is formed by melting polyamide 6 mixed with a first hydrophobic organosilicon material and a first compatibilizer, followed by spinning to produce a hydrophobic fiber bundle, which is then tufted onto the base fabric layer using a tufting machine. A water-based polyurethane foam latex mixed with a second hydrophobic organosilicon material and a second compatibilizer is then coated on the bottom of the base fabric layer to produce the adhesive layer, wherein the water contact angle of the adhesive layer is 100-105°. The first support layer, the reinforcement layer, the second support layer, and the bottom layer are then sequentially composited to produce the polymer hydrolysis-resistant composite carpet.

[0008] The heat-resistant dimensional stability of the polymer hydrolysis-resistant composite carpet is 0.51-0.72% in the warp direction and 0.57-0.78% in the weft direction. The water-immersion dimensional stability is 0.57-0.76% in the warp direction and 0.62-0.72% in the weft direction.

[0009] The polymer hydrolysis-resistant composite carpet has a water immersion color fastness of 4.5-5, a light color fastness of ≥4, and a color fastness after detergent and gasoline testing of ≥4;

[0010] The polymer hydrolysis-resistant composite carpet has a tuft pull-out force of 21-25N, a tuft pull-out force of 20-25N after being immersed in water, a wear-resistant circle number of ≥2900 circles without leakage, and a peeling force of 28-34N.

[0011] Furthermore, the polymer hydrolysis-resistant composite carpet has a thickness of 10-14 mm, a pile height of 3-5 mm, and a pile head in the form of cut pile.

[0012] Furthermore, the polymer hydrolysis-resistant composite carpet has no cracks, delamination, blistering, shrinkage, deformation, or irritating odor after being placed at -40°C for 24 hours, at 90°C for 168 hours, or irradiated with light.

[0013] The present invention also provides a method for preparing the polymer hydrolysis-resistant composite carpet, comprising the following steps:

[0014] Step 1, adding polyamide 6, a compatibilizer 1, an organosilicon material 1 and a masterbatch into a high-speed mixer and stirring and mixing to obtain a mixture, extruding the mixture through a screw extruder for spinning, the materials are melt-blended in the screw extruder and then spun through a spinneret, and rapidly air-cooled to obtain hydrophobic fiber filaments;

[0015] Step 2: oiling the hydrophobic fiber filaments, performing primary stretching on the oiled hydrophobic fiber filaments, and then performing secondary stretching on the stretched hydrophobic fiber filaments; then jet puffing the stretched hydrophobic fiber filaments, cooling them with a cooling roller, knotting the hydrophobic fiber filaments in a spinning net, and winding them with a winder to obtain a hydrophobic fiber bundle;

[0016] Step 3: providing a non-woven base fabric, and tufting the hydrophobic fiber bundle onto the non-woven base fabric to obtain a hydrophobic pile layer and a base fabric layer;

[0017] Step 4: mixing the waterborne polyurethane foam latex, the second compatibilizer and the second organosilicon material, and applying the mixture to the bottom of the base fabric layer, and drying the mixture to obtain an adhesive layer;

[0018] Step 5: After bonding the polyethylene-polyamide-polyethylene film (PEPAPE) with a laminating adhesive at the bottom of the adhesive layer, the needle-punched base felt is further bonded with a laminating adhesive, and after cooling, a first support layer and a reinforcing layer are obtained; after bonding the polyethylene-polyamide-polyethylene film (PEPAPE) with a laminating adhesive at the bottom of the reinforcing layer, a non-woven base fabric is further bonded with a laminating adhesive, and after cooling, a second support layer and a base layer are obtained; and finally, the polymer hydrolysis-resistant composite carpet is obtained.

[0019] Furthermore, in step 1, the speed of the high-speed mixer is 600-800 rpm, and the mixing time of the high-speed mixer is 2-4 min.

[0020] Furthermore, in the step 1, the mass ratio of the polyamide 6, the compatibilizer 1, the organosilicon material 1 and the masterbatch is (80:5:8:2)-(80:8:10:3).

[0021] Furthermore, the compatibilizer 1 in step 1 is maleic anhydride grafted polyamide.

[0022] Furthermore, the first organosilicon material in step 1 is a polyester-modified organosilicon resin.

[0023] Furthermore, the processing temperature of the screw extruder in step 1 is 220-260°C, which is divided into four temperature zones, wherein the temperature of the first temperature zone is 220-230°C, the temperature of the second temperature zone is 240-250°C, the temperature of the third temperature zone is 250-260°C, and the temperature of the fourth temperature zone is 240-250°C.

[0024] Furthermore, the number of holes of the spinneret in step 1 is 50-60, and the spinneret is a trilobal spinneret.

[0025] Furthermore, the air cooling temperature in step 1 is 15-25°C.

[0026] Furthermore, the type of oiling in step 2 is monohydroxy silicone oil, and the oiling rate is 0.6-0.8%.

[0027] Furthermore, the temperature of the primary stretching in step 2 is 80-90° C., and the stretching ratio is 1.01.

[0028] Furthermore, the temperature of the secondary stretching in step 2 is 170-190° C., and the stretching ratio is 2.3.

[0029] Furthermore, in step 2, the puffing temperature is 170-200° C., and the jet nozzle pressure is 4-5 bar.

[0030] Furthermore, in step 2, the temperature of the cooling roller is 20-25° C., and the rotation speed is 30-40 rpm.

[0031] Furthermore, the number of knots in step 2 is (25-27)±1, and the gas pressure of the spinning network device is 3-4 bar.

[0032] Furthermore, the total curl of the hydrophobic fiber bundle in step 2 is 15-18%, the fineness is 1500-1900D, and the number of holes is 50-60.

[0033] Furthermore, the non-woven fabric in step 3 has a gram weight of 120-140 gsm, and is a polyethylene terephthalate (PET) non-woven fabric.

[0034] Furthermore, the tufting in step 3 has a needle pitch of 1 / 10 or 5 / 64, a weft knitting density of 39.37 needles / cm or 50.39 needles / cm, a warp knitting density of 50-60 needles / cm, a needling depth of 5-6 mm, and a needle frequency of 800-1000 rpm.

[0035] Furthermore, in step 4, the mass ratio of the aqueous polyurethane foam latex, the second compatibilizer and the second organosilicon material is (4:1:1)-(4:1:2).

[0036] Furthermore, the foaming ratio of the waterborne polyurethane foam latex in step 4 is 2.0-3.0 times.

[0037] Furthermore, the second compatibilizer in step 4 is maleic anhydride grafted polyolefin elastomer.

[0038] Furthermore, the second organosilicon material in step 4 is a polyester-modified organosilicon resin.

[0039] Furthermore, in step 4, the stirring speed is 600-800 rpm, and the stirring time is 8-10 min.

[0040] Furthermore, the coating speed in step 4 is 8-15 m / min.

[0041] Furthermore, the drying temperature in step 4 is 130-190° C., and the drying time is 2-4 minutes.

[0042] Furthermore, the adhesive layer in step 4 has a gram weight of 50-130 gsm.

[0043] Furthermore, the laminating speed in step 5 is 3-4 m / min, and the laminating temperature is 230-250°C.

[0044] Furthermore, the binders in step 5 are all polyethylene, and the gram weight is 200-500gsm.

[0045] Furthermore, the needle-punched base felt in step 5 is a polyethylene terephthalate (PET) needle-punched base felt.

[0046] Furthermore, the gram weight of the support layer 1 in step 5 is 100-300 gsm.

[0047] Furthermore, the gram weight of the reinforcement layer in step 5 is 300-400 gsm.

[0048] Furthermore, the non-woven base fabric in step 5 is a polyethylene terephthalate (PET) non-woven base fabric.

[0049] Furthermore, the weight of the second support layer in step 5 is 100-300 gsm.

[0050] Furthermore, the bottom layer in step 5 has a gram weight of 200-300 gsm.

[0051] The present invention also provides an automobile carpet, which is prepared from the polymer hydrolysis-resistant composite carpet.

[0052] Beneficial effects of the present invention:

[0053] 1. In the present invention, polyamide 6 is used as a matrix, mixed with polyester-modified silicone resin, and a compatibilizer is used to improve the compatibilizer of the two, thereby reducing the incompatibility problem caused by the silicone material. The polyester-modified silicone resin migrates to the fiber surface to form a low surface energy structure, giving the fiber hydrophobicity. The maleic anhydride-grafted polyamide enhances the interfacial compatibility between polyamide 6 and the silicone resin, avoids material phase separation, ensures the stability of the fiber mechanical properties, and improves the hydrophobicity of the pile layer. Then, it is melt-spun with a masterbatch at a specific mixing temperature. At this temperature, the polyamide 6 and the silicone material are fully mixed without destroying their molecular structures. At the same time, a trilobal spinneret is used in combination with an air cooling process to give the fiber a special cross-section and a rapid shaping effect, thereby increasing the fiber specific surface area and cohesion. Finally, after secondary stretching, the fiber structure is further optimized, the molecular chain orientation and curl are improved, and the fiber has good elasticity and wear resistance. The monohydroxy silicone oil in the oiling process further improves the hydrophobicity of the fiber bundle.

[0054] 2. The present invention uses the above-mentioned hydrophobic fiber bundles to prepare a pile layer under a specific tufting process. The high-density tufting ensures the firmness and wear resistance of the pile, and different layers are compounded step by step, so that the layers of the composite carpet have different functions. The hydrophobic pile layer is waterproof and anti-fouling by virtue of the hydrophobic fiber bundles; the adhesive layer uses a combination of water-based polyurethane foam latex and silicone material to ensure that the pile is firmly bonded to the base fabric while reducing odor; the support layer and the reinforcement layer are compounded with PET material and PEPAPE coating to enhance the overall strength and stability of the carpet. The final composite carpet performs well in terms of hydrolysis resistance, wear resistance, high and low temperature resistance, color fastness, etc. Whether facing water erosion, high-frequency trampling, or extreme temperature and light environments, it can maintain structural integrity and stable performance, showing reliability and durability far exceeding conventional carpets. BRIEF DESCRIPTION OF THE DRAWINGS

[0055] Figure 1 This is a gasoline resistance test chart of the polymer hydrolysis-resistant composite carpet described in Example 1;

[0056] Figure 2 Graphs before and after high temperature resistance testing of the polymer hydrolysis-resistant composite carpet described in Examples 1-3;

[0057] Figure 3 These are the before and after pictures of the low temperature resistance test of the polymer hydrolysis-resistant composite carpet described in Examples 1-3;

[0058] Figure 4 These are the pictures showing the effects of the polymer hydrolysis-resistant composite carpet described in Examples 1-3 before and after illumination. DETAILED DESCRIPTION

[0059] The invention is described in detail below with reference to the embodiments:

[0060] The present invention provides a polymer hydrolysis-resistant composite carpet, a preparation method and an application thereof. By preparing a hydrophobic fiber bundle and an adhesive layer, the hydrolysis resistance of the composite carpet is greatly improved, and the mechanical properties, weather resistance and corrosion resistance of the composite carpet are also improved.

[0061] Example 1

[0062] This embodiment provides a polymeric hydrolysis-resistant composite carpet. The polymeric hydrolysis-resistant composite carpet comprises, from bottom to top, a base layer, a second support layer, a reinforcement layer, a first support layer, an adhesive layer, a base fabric layer, and a hydrophobic pile layer. The hydrophobic pile layer is formed by melt-spinning a polyamide 6 mixed with a polyester-modified silicone resin and maleic anhydride-grafted polyamide to produce a hydrophobic fiber bundle, which is then tufted onto the base fabric layer using a tufting machine. A water-based polyurethane foam latex mixed with a polyester-modified silicone resin and a maleic anhydride-grafted polyolefin elastomer is then coated on the bottom of the base fabric layer to produce the adhesive layer, which has a water contact angle of 103°. The first support layer, the reinforcement layer, the second support layer, and the base layer are then sequentially laminated to produce the polymeric hydrolysis-resistant composite carpet.

[0063] The polymer hydrolysis-resistant composite carpet has a thickness of 10 mm, a pile height of 4 mm, a cut pile shape, a tuft pull-out force of 24 N, and a tuft pull-out force of 23 N after immersion in water.

[0064] The heat-resistant dimensional stability of the polymer hydrolysis-resistant composite carpet is 0.51% in the warp direction and 0.58% in the weft direction;

[0065] The dimensional stability of the polymer hydrolysis-resistant composite carpet in water is 0.57% in the warp direction and 0.64% in the weft direction;

[0066] The polymer hydrolysis-resistant composite carpet has a water immersion color fastness of 4.5, a light color fastness of 4, and a detergent and gasoline resistance color fastness of 4.

[0067] The polymer hydrolysis-resistant composite carpet has a wear-resistant lap number of 3000 laps without leakage and a peeling force of 34N;

[0068] The polymer hydrolysis-resistant composite carpet has no cracks, delamination, blistering, shrinkage, deformation, or irritating odor after being placed at -40°C for 24 hours (low temperature resistance), at 90°C for 168 hours (high temperature resistance), or after being irradiated with light.

[0069] This embodiment also provides a method for preparing the polymer hydrolysis-resistant composite carpet, comprising the following steps:

[0070] Step 1. Add polyamide 6, maleic anhydride grafted polyamide, polyester modified silicone resin and masterbatch in a mass ratio of 80:5:8:2 into a high-speed mixer at 800 rpm and stir and mix for 2 minutes to obtain a mixture. The mixture is extruded and spun through a screw extruder. The processing temperature of the screw extruder is 220-250°C, and the screw extruder is divided into four temperature zones, wherein the temperature of the first temperature zone is 220°C, the temperature of the second temperature zone is 240°C, the temperature of the third temperature zone is 250°C, and the temperature of the fourth temperature zone is 240°C. After the materials are melt-blended in the screw extruder, they are spun through a trilobal spinneret having 50 holes. The hydrophobic fiber is quickly cooled at 15°C to obtain the hydrophobic fiber.

[0071] Step 2, oiling the hydrophobic fiber filaments, the oiling type is monohydroxy silicone oil, the oiling rate is 0.6%, and the hydrophobic fiber filaments after oiling are subjected to primary stretching, the temperature of the primary stretching is 80°C, the stretching ratio is 1.01, and then to secondary stretching, the temperature of the secondary stretching is 170°C, and the stretching ratio is 2.3; then the stretched hydrophobic fiber filaments are subjected to jet expansion at 170°C and a nozzle pressure of 5 bar, cooled by a cooling roller, the temperature of the cooling roller is 25°C, and the speed is 30 rpm, and the hydrophobic fiber filaments are continued to be knotted in a spinning network device, the number of knots is 25±1, the gas pressure of the spinning network device is 4 bar, and the hydrophobic fiber bundles are obtained after winding by a winder;

[0072] The hydrophobic fiber bundle has a total curl of 15%, a fineness of 1500D, and 50 pores;

[0073] Step 3: Prepare a 120 gsm polyethylene terephthalate (PET) non-woven base fabric, and tuft the hydrophobic fiber bundle onto the non-woven base fabric. The tufting has a needle pitch of 1 / 10, a weft knitting density of 39.37 needles / cm, a warp knitting density of 50 needles / cm, a needling depth of 5.5 mm, and a needle frequency of 1000 rpm to obtain a hydrophobic pile layer and a base fabric layer.

[0074] Step 4: stirring waterborne polyurethane foam latex (foaming ratio of 2.0 times), maleic anhydride grafted polyolefin elastomer (maleic anhydride grafted POE), and polyester modified silicone resin at a mass ratio of 4:1:1 at 800 rpm for 8 minutes, coating the mixture on the bottom of the base fabric layer at a speed of 10 m / min, and drying the mixture at 150° C. for 3 minutes to obtain a 100 gsm adhesive layer;

[0075] Step 5: Laminating a 300 gsm polyethylene bonded polyethylene-polyamide-polyethylene film (PEPAPE) at a speed of 3 m / min at 230° C. on the bottom of the adhesive layer, followed by laminating a 300 gsm polyethylene bonded polyethylene terephthalate (PET) needle-punched base felt, and cooling to obtain a 100 gsm support layer 1 and a 300 gsm reinforcement layer; continuously laminating a 300 gsm polyethylene bonded polyethylene-polyamide-polyethylene film (PEPAPE) at a speed of 3 m / min at 230° C. on the bottom of the reinforcement layer, followed by laminating a 300 gsm polyethylene bonded polyethylene terephthalate (PET) non-woven base fabric, and cooling to obtain a 100 gsm support layer 2 and a 200 gsm bottom layer; and finally obtaining the polymer hydrolysis-resistant composite carpet.

[0076] like Figure 1 This is a gasoline resistance test chart of the polymer hydrolysis-resistant composite carpet in Example 1. As can be seen from the chart, the polymer hydrolysis-resistant composite carpet in this example did not change color or surface after the corrosion test.

[0077] Example 2

[0078] This embodiment provides a polymeric hydrolysis-resistant composite carpet. The polymeric hydrolysis-resistant composite carpet comprises, from bottom to top, a base layer, a second support layer, a reinforcement layer, a first support layer, an adhesive layer, a base fabric layer, and a hydrophobic pile layer. The hydrophobic pile layer is formed by melt-spinning a polyamide 6 mixed with a polyester-modified silicone resin and maleic anhydride-grafted polyamide to produce a hydrophobic fiber bundle, which is then tufted onto the base fabric layer using a tufting machine. A water-based polyurethane foam latex mixed with a polyester-modified silicone resin and a maleic anhydride-grafted polyolefin elastomer is then coated on the bottom of the base fabric layer to produce the adhesive layer, which has a water contact angle of 100°. The first support layer, the reinforcement layer, the second support layer, and the base layer are then sequentially laminated to produce the polymeric hydrolysis-resistant composite carpet.

[0079] The polymer hydrolysis-resistant composite carpet has a thickness of 12 mm, a pile height of 3 mm, a cut pile shape, a tuft pull-out force of 21 N, and a tuft pull-out force of 20 N after immersion in water.

[0080] The heat-resistant dimensional stability of the polymer hydrolysis-resistant composite carpet is 0.72% in the warp direction and 0.76% in the weft direction;

[0081] The dimensional stability of the polymer hydrolysis-resistant composite carpet in water is 0.66% in the warp direction and 0.71% in the weft direction;

[0082] The polymer hydrolysis-resistant composite carpet has a water immersion color fastness of level 5, a light color fastness of level 4, and a detergent and gasoline resistance color fastness of level 5;

[0083] The polymer hydrolysis-resistant composite carpet has a wear-resistant lap number of 3000 laps without leakage and a peeling force of 28N;

[0084] The polymer hydrolysis-resistant composite carpet has no cracks, delamination, blistering, shrinkage, deformation, or irritating odor after being placed at -40°C for 24 hours, at 90°C for 168 hours, or irradiated with light.

[0085] This embodiment also provides a method for preparing the polymer hydrolysis-resistant composite carpet, comprising the following steps:

[0086] Step 1: Add polyamide 6, maleic anhydride grafted polyamide, polyester modified silicone resin and masterbatch in a mass ratio of 80:7:8:3 into a high-speed mixer at 700 rpm and stir for 7 minutes to obtain a mixture, and extrude the mixture through a screw extruder for spinning. The processing temperature of the screw extruder is 230-260°C, and the screw extruder is divided into four temperature zones, wherein the temperature of the first temperature zone is 230°C, the temperature of the second temperature zone is 250°C, the temperature of the third temperature zone is 260°C, and the temperature of the fourth temperature zone is 240°C. After the materials are melt-blended in the screw extruder, they are spun through a trilobal spinneret having 55 holes, and the hydrophobic fiber is obtained after rapid air cooling at 20°C.

[0087] Step 2, oiling the hydrophobic fiber filaments, the oiling type is monohydroxy silicone oil, the oiling rate is 0.8%, and the hydrophobic fiber filaments after oiling are subjected to primary stretching, the temperature of the primary stretching is 85°C, the stretching ratio is 1.01, and then to secondary stretching, the temperature of the secondary stretching is 190°C, and the stretching ratio is 2.3; then the stretched hydrophobic fiber filaments are subjected to jet puffing at 170°C and a nozzle pressure of 5 bar, cooled by a cooling roller, the temperature of the cooling roller is 25°C, and the speed is 30 rpm, and the hydrophobic fiber filaments are continued to be knotted in a spinning network device, the number of knots is 26±1, the gas pressure of the spinning network device is 4 bar, and the hydrophobic fiber bundles are obtained after winding by a winder;

[0088] The hydrophobic fiber bundle has a total curl of 16%, a fineness of 1900D, and 55 pores;

[0089] Step 3: Prepare a 130 gsm polyethylene terephthalate (PET) non-woven base fabric, and tuft the hydrophobic fiber bundle onto the non-woven base fabric, with the tufting having a needle pitch of 1 / 10, a weft knitting density of 39.37 needles / cm, a warp knitting density of 55 needles / cm, a needling depth of 5 mm, and a needle frequency of 1000 rpm, to obtain a hydrophobic pile layer and a base fabric layer;

[0090] Step 4: After stirring waterborne polyurethane foam latex (foaming ratio of 2.0 times), maleic anhydride grafted polyolefin elastomer and polyester modified silicone resin at a mass ratio of 4:1:2 at 800 rpm for 8 minutes, the mixture was coated on the bottom of the base fabric layer at a speed of 15 m / min and dried at 190° C. for 2 minutes to obtain a 130 gsm adhesive layer;

[0091] Step 5: Laminating a 200 gsm polyethylene bonded polyethylene-polyamide-polyethylene film (PEPAPE) at a speed of 3 m / min at 230° C. on the bottom of the adhesive layer, followed by laminating a 200 gsm polyethylene bonded polyethylene terephthalate (PET) needle-punched base felt, and cooling to obtain a 200 gsm support layer 1 and a 400 gsm reinforcement layer; continuously laminating a 200 gsm polyethylene bonded polyethylene-polyamide-polyethylene film (PEPAPE) at a speed of 3 m / min at 230° C. on the bottom of the reinforcement layer, followed by laminating a 200 gsm polyethylene bonded polyethylene terephthalate (PET) non-woven base fabric, and cooling to obtain a 200 gsm support layer 2 and a 300 gsm bottom layer; and finally obtaining the polymer hydrolysis-resistant composite carpet.

[0092] Example 3

[0093] This embodiment provides a polymeric hydrolysis-resistant composite carpet. The polymeric hydrolysis-resistant composite carpet comprises, from bottom to top, a base layer, a second support layer, a reinforcement layer, a first support layer, an adhesive layer, a base fabric layer, and a hydrophobic pile layer. The hydrophobic pile layer is formed by melt-spinning a polyamide 6 mixed with a polyester-modified silicone resin and maleic anhydride-grafted polyamide to produce a hydrophobic fiber bundle, which is then tufted onto the base fabric layer using a tufting machine. A water-based polyurethane foam latex mixed with a polyester-modified silicone resin and a maleic anhydride-grafted polyolefin elastomer is then coated on the bottom of the base fabric layer to produce the adhesive layer, which has a water contact angle of 105°. The first support layer, the reinforcement layer, the second support layer, and the base layer are then sequentially laminated to produce the polymeric hydrolysis-resistant composite carpet.

[0094] The polymer hydrolysis-resistant composite carpet has a thickness of 14 mm, a pile height of 5 mm, a cut pile shape, and a tuft pull-out force of 25 N. The tuft pull-out force after immersion in water is 25 N.

[0095] The heat-resistant dimensional stability of the polymer hydrolysis-resistant composite carpet is 0.61% in the warp direction and 0.57% in the weft direction;

[0096] The dimensional stability of the polymer hydrolysis-resistant composite carpet in water is 0.69% in the warp direction and 0.62% in the weft direction;

[0097] The polymer hydrolysis-resistant composite carpet has a water immersion color fastness of 4.5, a light color fastness of 4, and a detergent and gasoline resistance color fastness of 5;

[0098] The polymer hydrolysis-resistant composite carpet has a wear-resistant lap number of 2900 laps without leakage and a peeling force of 29N;

[0099] The polymer hydrolysis-resistant composite carpet has no cracks, delamination, blistering, shrinkage, deformation, or irritating odor after being placed at -40°C for 24 hours, at 90°C for 168 hours, or irradiated with light.

[0100] This embodiment also provides a method for preparing the polymer hydrolysis-resistant composite carpet, comprising the following steps:

[0101] Step 1: Add polyamide 6, maleic anhydride grafted polyamide, polyester modified silicone resin and masterbatch in a mass ratio of 80:8:10:2 into a high-speed mixer at 600 rpm and stir for 4 minutes to obtain a mixture, and extrude the mixture through a screw extruder for spinning. The processing temperature of the screw extruder is 220-250°C, and the screw extruder is divided into four temperature zones, wherein the temperature of the first temperature zone is 220°C, the temperature of the second temperature zone is 240°C, the temperature of the third temperature zone is 250°C, and the temperature of the fourth temperature zone is 240°C. After the materials are melt-blended in the screw extruder, they are spun through a trilobal spinneret having 60 holes, and the hydrophobic fiber is obtained after rapid air cooling at 25°C.

[0102] Step 2, oiling the hydrophobic fiber filaments, the oiling type is monohydroxy silicone oil, the oiling rate is 0.7%, and the hydrophobic fiber filaments after oiling are subjected to primary stretching, the temperature of the primary stretching is 90°C, the stretching ratio is 1.01, and then to secondary stretching, the temperature of the secondary stretching is 180°C, and the stretching ratio is 2.3; then the stretched hydrophobic fiber filaments are subjected to jet expansion at 170°C and a nozzle pressure of 4 bar, and cooled by a cooling roller, the temperature of the cooling roller is 20°C, and the speed is 30 rpm. The hydrophobic fiber filaments are further knotted in a spinning network device, the number of knots is 27±1, the gas pressure of the spinning network device is 3 bar, and the hydrophobic fiber bundles are obtained after winding by a winder;

[0103] The hydrophobic fiber bundle has a total curl of 15%, a fineness of 1800D, and 60 pores;

[0104] Step 3: Prepare a 120 gsm polyethylene terephthalate (PET) non-woven base fabric, and tuft the hydrophobic fiber bundle onto the non-woven base fabric. The tufting has a needle pitch of 1 / 10, a weft knitting density of 39.37 needles / cm, a warp knitting density of 60 needles / cm, a needling depth of 6 mm, and a needle frequency of 800 rpm to obtain a hydrophobic pile layer and a base fabric layer.

[0105] Step 4: stirring waterborne polyurethane foam latex (foaming ratio of 3.0 times), maleic anhydride grafted polyolefin elastomer, and polyester modified silicone resin at a mass ratio of 4:1:1 at 700 rpm for 9 minutes, coating the mixture on the bottom of the base fabric layer at a speed of 9 m / min, and drying the mixture at 130° C. for 4 minutes to obtain a 50 gsm adhesive layer;

[0106] Step 5: Laminating a 500 gsm polyethylene bonded polyethylene-polyamide-polyethylene film (PEPAPE) at a speed of 4 m / min at 240° C. on the bottom of the adhesive layer, followed by laminating a 500 gsm polyethylene bonded polyethylene terephthalate (PET) needle-punched base felt, and cooling to obtain a 300 gsm support layer 1 and a 300 gsm reinforcement layer; continuously laminating a 500 gsm polyethylene bonded polyethylene-polyamide-polyethylene film (PEPAPE) at a speed of 3 m / min at 230° C. on the bottom of the reinforcement layer, followed by laminating a 500 gsm polyethylene bonded polyethylene terephthalate (PET) non-woven base fabric, and cooling to obtain a 300 gsm support layer 2 and a 200 gsm base layer; and finally obtaining the polymer hydrolysis-resistant composite carpet.

[0107] like Figure 2-4 These are the high temperature resistance, low temperature resistance and light irradiation effect diagrams of the polymer hydrolysis-resistant composite carpet described in Examples 1-3. In the diagrams, there is no obvious change on the surface of the carpet after the test.

[0108] Example 4

[0109] This embodiment provides a polymeric hydrolysis-resistant composite carpet. The polymeric hydrolysis-resistant composite carpet comprises, from bottom to top, a base layer, a second support layer, a reinforcement layer, a first support layer, an adhesive layer, a base fabric layer, and a hydrophobic pile layer. The hydrophobic pile layer is formed by melt-spinning a polyamide 6 mixed with a polyester-modified silicone resin and maleic anhydride-grafted polyamide to produce a hydrophobic fiber bundle, which is then tufted onto the base fabric layer using a tufting machine. A water-based polyurethane foam latex mixed with a polyester-modified silicone resin and a maleic anhydride-grafted polyolefin elastomer is then coated on the bottom of the base fabric layer to produce the adhesive layer, which has a water contact angle of 102°. The first support layer, the reinforcement layer, the second support layer, and the base layer are then sequentially laminated to produce the polymeric hydrolysis-resistant composite carpet.

[0110] The polymer hydrolysis-resistant composite carpet has a thickness of 10 mm, a pile height of 4 mm, a cut pile shape, a tuft pull-out force of 22 N, and a tuft pull-out force of 20 N after immersion in water.

[0111] The heat-resistant dimensional stability of the polymer hydrolysis-resistant composite carpet is 0.72% in the warp direction and 0.78% in the weft direction;

[0112] The dimensional stability of the polymer hydrolysis-resistant composite carpet in water is 0.76% in the warp direction and 0.72% in the weft direction;

[0113] The polymer hydrolysis-resistant composite carpet has a water immersion color fastness of level 5, a light color fastness of level 4, and a detergent and gasoline resistance color fastness of level 4;

[0114] The polymer hydrolysis-resistant composite carpet has a wear-resistant lap number of 2950 laps without leakage and a peeling force of 33N;

[0115] The polymer hydrolysis-resistant composite carpet has no cracks, delamination, blistering, shrinkage, deformation, or irritating odor after being placed at -40°C for 24 hours, at 90°C for 168 hours, or irradiated with light.

[0116] This embodiment also provides a method for preparing the polymer hydrolysis-resistant composite carpet, comprising the following steps:

[0117] Step 1, adding polyamide 6, maleic anhydride grafted polyamide, polyester modified silicone resin and masterbatch in a mass ratio of 80:5:10:2 into a high-speed mixer at 800 rpm and stirring for 2 minutes to obtain a mixture, and extruding the mixture through a screw extruder for spinning. The processing temperature of the screw extruder is 220-250°C, and is divided into four temperature zones, wherein the temperature of the first temperature zone is 220°C, the temperature of the second temperature zone is 240°C, the temperature of the third temperature zone is 250°C, and the temperature of the fourth temperature zone is 240°C. After the materials are melt-blended in the screw extruder, they are spun through a trilobal spinneret, the number of holes of the trilobal spinneret is 50, and the hydrophobic fiber is obtained after rapid air cooling at 15°C;

[0118] Step 2, oiling the hydrophobic fiber filaments, the oiling type is monohydroxy silicone oil, the oiling rate is 0.6%, and the oiled hydrophobic fiber filaments are subjected to primary stretching, the primary stretching temperature is 80°C, the stretching ratio is 1.01, and then the secondary stretching is performed, the secondary stretching temperature is 170°C, and the stretching ratio is 2.3; then the stretched hydrophobic fiber filaments are subjected to jet puffing at 200°C and a nozzle pressure of 5 bar, cooled by a cooling roller, the temperature of the cooling roller is 25°C, and the speed is 40 rpm, and the hydrophobic fiber filaments are continued to be knotted in a spinning network device, the number of knots is 25±1, the gas pressure of the spinning network device is 4 bar, and the hydrophobic fiber bundles are obtained after winding by a winder;

[0119] The hydrophobic fiber bundle has a total curl of 18%, a fineness of 1500D, and 50 pores;

[0120] Step 3: A 140 gsm polyethylene terephthalate (PET) non-woven fabric was prepared, and the hydrophobic fiber bundles were tufted onto the non-woven fabric. The tufting had a needle pitch of 5 / 64, a weft knitting density of 50.39 needles / cm, a warp knitting density of 50 needles / cm, a needling depth of 5.5 mm, and a needle frequency of 1000 rpm, to obtain a hydrophobic pile layer and a base fabric layer.

[0121] Step 4: stirring waterborne polyurethane foam latex (foaming ratio of 2.0 times), maleic anhydride grafted polyolefin elastomer, and polyester modified silicone resin at a mass ratio of 4:1:1 at 600 rpm for 10 minutes, coating the mixture on the bottom of the base fabric layer at a speed of 10 m / min, and drying the mixture at 140° C. for 4 minutes to obtain a 100 gsm adhesive layer;

[0122] Step 5: Laminating a 400 gsm polyethylene bonded polyethylene-polyamide-polyethylene film (PEPAPE) at a speed of 3 m / min at 250° C. on the bottom of the adhesive layer, followed by laminating a 400 gsm polyethylene bonded polyethylene terephthalate (PET) needle-punched base felt, and cooling to obtain a 100 gsm support layer 1 and a 400 gsm reinforcement layer; continuously laminating a 400 gsm polyethylene bonded polyethylene-polyamide-polyethylene film (PEPAPE) at a speed of 3 m / min at 230° C. on the bottom of the reinforcement layer, followed by laminating a 400 gsm polyethylene bonded polyethylene terephthalate (PET) non-woven base fabric, and cooling to obtain a 200 gsm support layer 2 and a 300 gsm bottom layer; and finally obtaining the polymer hydrolysis-resistant composite carpet.

[0123] Comparative Example 1

[0124] This comparative example provides a composite carpet, comprising, from bottom to top, a base layer, a second support layer, a reinforcement layer, a first support layer, an adhesive layer, a base fabric layer, and a pile layer; the pile layer is formed by melting polyamide 6 and a masterbatch and spinning them into a fiber bundle, which is then tufted onto the base fabric layer using a tufting machine; a water-based polyurethane foam latex mixed with a polyester-modified silicone resin and a maleic anhydride-grafted polyolefin elastomer is then coated on the bottom of the base fabric layer to form the adhesive layer, the adhesive layer having a water contact angle of 102°; and the first support layer, the reinforcement layer, the second support layer, and the base layer are then sequentially laminated to produce the composite carpet.

[0125] The composite carpet has a thickness of 10 mm, a pile height of 4 mm, a cut pile shape, a tuft pull-out force of 18 N, and a tuft pull-out force of 16 N after immersion in water.

[0126] The composite carpet has a heat-resistant dimensional stability of 1.01% in the warp direction and 1.00% in the weft direction;

[0127] The composite carpet has a water immersion dimensional stability of 1.23% in the warp direction and 1.21% in the weft direction;

[0128] The composite carpet has a color fastness to water immersion of 3.5, a color fastness to light of 3.5, and a color fastness to detergent and gasoline of 4;

[0129] The composite carpet has a wear-resistant circle number of 2900 circles without leakage and a peeling force of 22N.

[0130] This comparative example also provides a method for preparing the composite carpet, comprising the following steps:

[0131] Step 1, adding polyamide 6 and masterbatch with a mass ratio of 80:2 into a high-speed mixer at 800 rpm and stirring for 2 minutes to obtain a mixture, and extruding the mixture through a screw extruder for spinning. The processing temperature of the screw extruder is 220-250°C, and is divided into four temperature zones, wherein the temperature of the first temperature zone is 220°C, the temperature of the second temperature zone is 240°C, the temperature of the third temperature zone is 250°C, and the temperature of the fourth temperature zone is 240°C. After the materials are melt-blended in the screw extruder, they are spun through a trilobal spinneret, the number of holes of the trilobal spinneret is 50, and the fibers are quickly air-cooled at 15°C to obtain fiber filaments;

[0132] Step 2, oiling the fiber filaments, the oiling type is monohydroxy silicone oil, the oiling rate is 0.6%, and the fiber filaments after oiling are subjected to primary stretching, the primary stretching temperature is 80°C, the stretching ratio is 1.01, and then to secondary stretching, the secondary stretching temperature is 170°C, and the stretching ratio is 2.3; then the stretched fiber filaments are subjected to jet expansion at 170°C and a nozzle pressure of 5 bar, cooled by a cooling roller, the temperature of the cooling roller is 25°C, and the speed is 30 rpm, and the fiber filaments are continued to be knotted in a spinning network device, the number of knots is 25±1, the gas pressure of the spinning network device is 4 bar, and the fiber bundles are obtained after winding by a winder;

[0133] The fiber bundle has a total curl of 15%, a fineness of 1500D, and 50 holes;

[0134] Step 3: A 120 gsm polyethylene terephthalate (PET) non-woven fabric was prepared, and the fiber bundles were tufted onto the non-woven fabric. The tufting had a needle pitch of 1 / 10, a weft knitting density of 39.37 needles / cm, a warp knitting density of 50 needles / cm, a needling depth of 5.5 mm, and a needle frequency of 1000 rpm to obtain a hydrophobic pile layer and a base fabric layer.

[0135] Step 4: stirring waterborne polyurethane foam latex (foaming ratio of 2.0 times), maleic anhydride grafted polyolefin elastomer (maleic anhydride grafted POE), and polyester modified silicone resin at a mass ratio of 4:1:1 at 800 rpm for 8 minutes, coating the mixture on the bottom of the base fabric layer at a speed of 10 m / min, and drying the mixture at 150° C. for 3 minutes to obtain a 100 gsm adhesive layer;

[0136] Step 5: Laminating a 300 gsm polyethylene bonded polyethylene-polyamide-polyethylene film (PEPAPE) at a speed of 3 m / min at 230° C. on the bottom of the adhesive layer, followed by laminating a 300 gsm polyethylene bonded polyethylene terephthalate (PET) needle-punched base felt, and cooling to obtain a 200 gsm support layer 1 and a 300 gsm reinforcement layer; continuously laminating a 300 gsm polyethylene bonded polyethylene-polyamide-polyethylene film (PEPAPE) at a speed of 3 m / min at 230° C. on the bottom of the reinforcement layer, followed by laminating a 300 gsm polyethylene bonded polyethylene terephthalate (PET) non-woven base fabric, and cooling to obtain a 200 gsm support layer 2 and a 200 gsm bottom layer; and finally obtaining the polymer hydrolysis-resistant composite carpet.

[0137] Comparative Example 2

[0138] This comparative example provides a composite carpet, comprising, from bottom to top, a base layer, a second support layer, a reinforcement layer, a first support layer, an adhesive layer, a base fabric layer, and a hydrophobic pile layer; the hydrophobic pile layer is formed by melt-spinning a polyamide 6 mixed with a polyester-modified silicone resin and maleic anhydride-grafted polyamide to produce a hydrophobic fiber bundle, which is then tufted onto the base fabric layer using a tufting machine; a water-based polyurethane foam latex mixed with a polyester-modified silicone resin and a maleic anhydride-grafted polyolefin elastomer is then coated on the bottom of the base fabric layer to produce the adhesive layer, the adhesive layer having a water contact angle of 102°; and the support layer 1, the reinforcement layer, the second support layer, and the base layer are then sequentially laminated to produce the composite carpet.

[0139] The composite carpet has a thickness of 10 mm, a pile height of 4 mm, a cut pile shape, a tuft pull-out force of 19 N, and a tuft pull-out force of 15 N after immersion in water.

[0140] The composite carpet has a heat-resistant dimensional stability of 0.95% in the warp direction and 0.89% in the weft direction;

[0141] The composite carpet has a water immersion dimensional stability of 0.80% in the warp direction and 0.85% in the weft direction;

[0142] The composite carpet has a water immersion color fastness of level 4, a light color fastness of level 4, and a detergent and gasoline resistance color fastness of level 4;

[0143] The composite carpet has a wear-resistant number of 3000 turns without leakage and a peeling force of 23N.

[0144] This comparative example also provides a method for preparing the composite carpet, comprising the following steps:

[0145] Step 1. Add polyamide 6, maleic anhydride grafted polyamide, polyester modified silicone resin and masterbatch in a mass ratio of 80:5:8:2 into a high-speed mixer at 800 rpm and stir and mix for 2 minutes to obtain a mixture. The mixture is extruded and spun through a screw extruder. The processing temperature of the screw extruder is 220-250°C, and the screw extruder is divided into four temperature zones, wherein the temperature of the first temperature zone is 220°C, the temperature of the second temperature zone is 240°C, the temperature of the third temperature zone is 250°C, and the temperature of the fourth temperature zone is 240°C. After the materials are melt-blended in the screw extruder, they are spun through a trilobal spinneret having 50 holes. The hydrophobic fiber is quickly cooled at 15°C to obtain the hydrophobic fiber.

[0146] Step 2, oiling the hydrophobic fiber filaments, using a conventional spinning oil and an oiling rate of 0.6%, performing a primary stretching on the oiled hydrophobic fiber filaments, wherein the primary stretching temperature is 80°C and the stretching ratio is 1.01, and then performing a secondary stretching, wherein the secondary stretching temperature is 170°C and the stretching ratio is 2.3; then, the stretched hydrophobic fiber filaments are subjected to air-jet expansion at 170°C and a nozzle pressure of 5 bar, cooled by a cooling roller, wherein the temperature of the cooling roller is 25°C and the rotation speed is 30 rpm, and the hydrophobic fiber filaments are further knotted in a spinning network device, wherein the number of knots is 25±1, and the gas pressure of the spinning network device is 4 bar, and then wound on a winder to obtain a hydrophobic fiber bundle;

[0147] The hydrophobic fiber bundle has a total curl of 15%, a fineness of 1500D, and 50 pores;

[0148] Step 3: Prepare a 120 gsm polyethylene terephthalate (PET) non-woven base fabric, and tuft the hydrophobic fiber bundle onto the non-woven base fabric. The tufting has a needle pitch of 1 / 10, a weft knitting density of 39.37 needles / cm, a warp knitting density of 50 needles / cm, a needling depth of 5.5 mm, and a needle frequency of 1000 rpm to obtain a hydrophobic pile layer and a base fabric layer.

[0149] Step 4: stirring waterborne polyurethane foam latex (foaming ratio of 2.0 times), maleic anhydride grafted polyolefin elastomer (maleic anhydride grafted POE), and polyester modified silicone resin at a mass ratio of 4:1:1 at 800 rpm for 8 minutes, coating the mixture on the bottom of the base fabric layer at a speed of 10 m / min, and drying the mixture at 150° C. for 3 minutes to obtain a 100 gsm adhesive layer;

[0150] Step 5: Laminating a 300 gsm polyethylene bonded polyethylene-polyamide-polyethylene film (PEPAPE) at a speed of 3 m / min at 230° C. on the bottom of the adhesive layer, followed by laminating a 300 gsm polyethylene bonded polyethylene terephthalate (PET) needle-punched base felt, and cooling to obtain a 200 gsm support layer 1 and a 300 gsm reinforcement layer; continuously laminating a 300 gsm polyethylene bonded polyethylene-polyamide-polyethylene film (PEPAPE) at a speed of 3 m / min at 230° C. on the bottom of the reinforcement layer, followed by laminating a 300 gsm polyethylene bonded polyethylene terephthalate (PET) non-woven base fabric, and cooling to obtain a 200 gsm support layer 2 and a 200 gsm bottom layer; and finally obtaining the polymer hydrolysis-resistant composite carpet.

[0151] Comparative Example 3

[0152] This comparative example provides a composite carpet, comprising, from bottom to top, a base layer, a second support layer, a reinforcement layer, a first support layer, an adhesive layer, a base fabric layer, and a hydrophobic pile layer; the hydrophobic pile layer is formed by melt-spinning a polyamide 6 mixed polyester-modified silicone resin and a maleic anhydride-grafted polyamide to produce a hydrophobic fiber bundle, which is then tufted onto the base fabric layer using a tufting machine; the base fabric layer is then coated with a water-based polyurethane foam latex to produce the adhesive layer, which has a water contact angle of 47°; and the base fabric layer is then laminated in sequence with the first support layer, the reinforcement layer, the second support layer, and the base layer to produce the composite carpet.

[0153] The composite carpet has a thickness of 10 mm, a pile height of 4 mm, a cut pile shape, a tuft pull-out force of 17 N, and a tuft pull-out force of 14 N after immersion in water.

[0154] The composite carpet has a heat-resistant dimensional stability of 0.67% in the warp direction and 0.69% in the weft direction;

[0155] The composite carpet has a water immersion dimensional stability of 0.71% in the warp direction and 0.73% in the weft direction;

[0156] The composite carpet has a water immersion color fastness of 3.5, a light color fastness of 4, and a detergent and gasoline resistance color fastness of 4;

[0157] The composite carpet has a wear resistance of 2850 turns without leakage and a peeling force of 25N;

[0158] The composite carpet has no cracks, delamination, blistering, shrinkage, deformation, or irritating odor after being placed at -40°C for 24 hours (low temperature resistance), at 90°C for 168 hours (high temperature resistance), or after being exposed to light.

[0159] This comparative example also provides a method for preparing the composite carpet, comprising the following steps:

[0160] Step 1. Add polyamide 6, maleic anhydride grafted polyamide, polyester modified silicone resin and masterbatch in a mass ratio of 80:5:8:2 into a high-speed mixer at 800 rpm and stir and mix for 2 minutes to obtain a mixture. The mixture is extruded and spun through a screw extruder. The processing temperature of the screw extruder is 220-250°C, and the screw extruder is divided into four temperature zones, wherein the temperature of the first temperature zone is 220°C, the temperature of the second temperature zone is 240°C, the temperature of the third temperature zone is 250°C, and the temperature of the fourth temperature zone is 240°C. After the materials are melt-blended in the screw extruder, they are spun through a trilobal spinneret having 50 holes. The hydrophobic fiber is quickly cooled at 15°C to obtain the hydrophobic fiber.

[0161] Step 2, oiling the hydrophobic fiber filaments, the oiling type is monohydroxy silicone oil, the oiling rate is 0.6%, and the hydrophobic fiber filaments after oiling are subjected to primary stretching, the temperature of the primary stretching is 80°C, the stretching ratio is 1.01, and then to secondary stretching, the temperature of the secondary stretching is 170°C, and the stretching ratio is 2.3; then the stretched hydrophobic fiber filaments are subjected to jet expansion at 170°C and a nozzle pressure of 5 bar, cooled by a cooling roller, the temperature of the cooling roller is 25°C, and the speed is 30 rpm, and the hydrophobic fiber filaments are continued to be knotted in a spinning network device, the number of knots is 25±1, the gas pressure of the spinning network device is 4 bar, and the hydrophobic fiber bundles are obtained after winding by a winder;

[0162] The hydrophobic fiber bundle has a total curl of 15%, a fineness of 1500D, and 50 pores;

[0163] Step 3: Prepare a 120 gsm polyethylene terephthalate (PET) non-woven base fabric, and tuft the hydrophobic fiber bundle onto the non-woven base fabric. The tufting has a needle pitch of 1 / 10, a weft knitting density of 39.37 needles / cm, a warp knitting density of 50 needles / cm, a needling depth of 5.5 mm, and a needle frequency of 1000 rpm to obtain a hydrophobic pile layer and a base fabric layer.

[0164] Step 4: coating water-based polyurethane foam latex (with a foaming ratio of 2.0 times) on the bottom of the base fabric layer at a speed of 10 m / min, and drying at 150° C. for 3 minutes to obtain a 100 gsm adhesive layer;

[0165] Step 5: Laminating a 300 gsm polyethylene bonded polyethylene-polyamide-polyethylene film (PEPAPE) at a speed of 3 m / min at 230° C. on the bottom of the adhesive layer, followed by laminating a 300 gsm polyethylene bonded polyethylene terephthalate (PET) needle-punched base felt, and cooling to obtain a 200 gsm support layer 1 and a 300 gsm reinforcement layer; continuously laminating a 300 gsm polyethylene bonded polyethylene-polyamide-polyethylene film (PEPAPE) at a speed of 3 m / min at 230° C. on the bottom of the reinforcement layer, followed by laminating a 300 gsm polyethylene bonded polyethylene terephthalate (PET) non-woven base fabric, and cooling to obtain a 200 gsm support layer 2 and a 200 gsm bottom layer; and finally obtaining the polymer hydrolysis-resistant composite carpet.

[0166] Comparative Example 4

[0167] This comparative example provides a composite carpet, comprising, from bottom to top, a base layer, a second support layer, a reinforcement layer, a first support layer, an adhesive layer, a base fabric layer, and a hydrophobic pile layer; the hydrophobic pile layer is formed by melt-spinning a polyamide 6 mixed with a polyester-modified silicone resin and maleic anhydride-grafted polyamide to produce a hydrophobic fiber bundle, which is then tufted onto the base fabric layer using a tufting machine; a water-based polyurethane foam latex mixed with a polyester-modified silicone resin and a maleic anhydride-grafted polyolefin elastomer is then coated on the bottom of the base fabric layer to produce the adhesive layer, the adhesive layer having a water contact angle of 101°; and the support layer 1, the reinforcement layer, the second support layer, and the base layer are then sequentially laminated to produce the composite carpet.

[0168] The composite carpet has a thickness of 10 mm, a pile height of 4 mm, a cut pile shape, a tuft pull-out force of 17 N, and a tuft pull-out force of 15 N after immersion in water.

[0169] The composite carpet has a heat-resistant dimensional stability of 0.55% in the warp direction and 0.58% in the weft direction;

[0170] The composite carpet has a water immersion dimensional stability of 0.67% in the warp direction and 0.64% in the weft direction;

[0171] The composite carpet has a water immersion color fastness of level 4, a light color fastness of level 4, and a detergent and gasoline resistance color fastness of level 4;

[0172] The composite carpet has a wear resistance of 2500 turns without leakage and a peeling force of 19N;

[0173] The composite carpet has no cracks, delamination, blistering, shrinkage, deformation, or irritating odor after being placed at -40°C for 24 hours (low temperature resistance), at 90°C for 168 hours (high temperature resistance), or after being exposed to light.

[0174] This comparative example also provides a method for preparing the composite carpet, comprising the following steps:

[0175] Step 1. Add polyamide 6, maleic anhydride grafted polyamide, polyester modified silicone resin and masterbatch in a mass ratio of 80:3:10:2 into a high-speed mixer at 800 rpm and stir and mix for 2 minutes to obtain a mixture. The mixture is extruded and spun through a screw extruder. The processing temperature of the screw extruder is 220-250°C, and the screw extruder is divided into four temperature zones, wherein the temperature of the first temperature zone is 220°C, the temperature of the second temperature zone is 240°C, the temperature of the third temperature zone is 250°C, and the temperature of the fourth temperature zone is 240°C. After the materials are melt-blended in the screw extruder, they are spun through a trilobal spinneret having 50 holes. The hydrophobic fiber is quickly cooled at 15°C to obtain the hydrophobic fiber.

[0176] Step 2, oiling the hydrophobic fiber filaments, the oiling type is monohydroxy silicone oil, the oiling rate is 0.6%, and the hydrophobic fiber filaments after oiling are subjected to primary stretching, the temperature of the primary stretching is 80°C, the stretching ratio is 1.01, and then to secondary stretching, the temperature of the secondary stretching is 170°C, and the stretching ratio is 2.3; then the stretched hydrophobic fiber filaments are subjected to jet expansion at 170°C and a nozzle pressure of 5 bar, cooled by a cooling roller, the temperature of the cooling roller is 25°C, and the speed is 30 rpm, and the hydrophobic fiber filaments are continued to be knotted in a spinning network device, the number of knots is 25±1, the gas pressure of the spinning network device is 4 bar, and the hydrophobic fiber bundles are obtained after winding by a winder;

[0177] The hydrophobic fiber bundle has a total curl of 15%, a fineness of 1500D, and 50 pores;

[0178] Step 3: Prepare a 120 gsm polyethylene terephthalate (PET) non-woven base fabric, and tuft the hydrophobic fiber bundle onto the non-woven base fabric. The tufting has a needle pitch of 1 / 10, a weft knitting density of 39.37 needles / cm, a warp knitting density of 50 needles / cm, a needling depth of 5.5 mm, and a needle frequency of 1000 rpm to obtain a hydrophobic pile layer and a base fabric layer.

[0179] Step 4: stirring waterborne polyurethane foam latex (foaming ratio of 2.0 times), maleic anhydride grafted polyolefin elastomer (maleic anhydride grafted POE), and polyester modified silicone resin at a mass ratio of 4:1:1 at 800 rpm for 8 minutes, coating the mixture on the bottom of the base fabric layer at a speed of 10 m / min, and drying the mixture at 150° C. for 3 minutes to obtain a 100 gsm adhesive layer;

[0180] Step 5: Laminating a 300 gsm polyethylene bonded polyethylene-polyamide-polyethylene film (PEPAPE) at a speed of 3 m / min at 230° C. on the bottom of the adhesive layer, followed by laminating a 300 gsm polyethylene bonded polyethylene terephthalate (PET) needle-punched base felt, and cooling to obtain a 200 gsm support layer 1 and a 300 gsm reinforcement layer; continuously laminating a 300 gsm polyethylene bonded polyethylene-polyamide-polyethylene film (PEPAPE) at a speed of 3 m / min at 230° C. on the bottom of the reinforcement layer, followed by laminating a 300 gsm polyethylene bonded polyethylene terephthalate (PET) non-woven base fabric, and cooling to obtain a 200 gsm support layer 2 and a 200 gsm bottom layer; and finally obtaining the polymer hydrolysis-resistant composite carpet.

[0181] The type of the polyester-modified silicone resin in the present invention is not limited, and any existing polyester-modified silicone resin can be used;

[0182] The conventional spinning oil is a lipid fiber oil, and its ingredients include fatty acid glyceride, alkyl phosphate potassium salt and polyethylene glycol.

[0183] Table 1 shows the properties of the composite carpets in this embodiment and the comparative example.

[0184]

[0185] As can be seen from the table, the composite carpet in this embodiment has good stability, high color fastness, and excellent hydrolysis resistance, while also maintaining high mechanical properties and abrasion resistance. However, in Comparative Example 1, polyamide 6 was not modified with silicone, resulting in poor hydrophobicity of the pile layer, which also affected its temperature stability, color fastness, and hydrolysis resistance. In Comparative Example 2, monohydroxy silicone oil was not used, which reduced the hydrolysis resistance of the composite carpet and its stability. In Comparative Example 3, the adhesive layer consisted solely of water-based polyurethane foam latex, resulting in a significantly reduced water contact angle of the adhesive layer, which was significantly affected during the hydrolysis resistance test (color fastness and pull-out force after immersion in water). In Comparative Example 4, the mass ratio of the compatibilizer, silicone material, and polyamide 6 was increased. The increased mass of silicone material affected the fluidity of polyamide 6, affecting its fluidity during the spinning process, which in turn affected the properties of the fiber bundle and also led to a decrease in the mechanical properties and hydrolysis resistance of the composite carpet.

[0186] The heat-resistant dimensional stability test standard of the present invention is Q / JQ 5106-2014. The test conditions are as follows: a 300*300 mm polymer hydrolysis-resistant composite carpet is prepared, and its warp and weft dimensions L0 and L1 are tested. The polymer hydrolysis-resistant composite carpet is then placed in a high-temperature oven at 50°C for 8 hours, removed and cooled to room temperature, and its warp and weft dimensions L0' and L1' are tested again. The warp stability is calculated as (L0-L0') / L0*100%, and the weft stability is calculated as (L1-L1') / L1*100%.

[0187] The test standard for dimensional stability after immersion is Q / JQ 5106-2014. The test conditions are as follows: prepare a 300*300mm polymer hydrolysis-resistant composite carpet, test its warp and weft dimensions L2 and L3, then place the polymer hydrolysis-resistant composite carpet in room temperature water for 1 hour, remove it and drain it, and retest its warp and weft dimensions L2' and L3'. The warp stability is calculated as (L2-L2') / L2*100%, and the weft stability is calculated as (L3-L3') / L3*100%.

[0188] The test standard for the water immersion color fastness of the polymer hydrolysis-resistant composite carpet is "Q / JQ 5106-2014 5.9". The test conditions are as follows: after the polymer hydrolysis-resistant composite carpet is placed at 20°C and 60% RH for 24 hours, a filter paper soaked in deionized water is placed on the polymer hydrolysis-resistant composite carpet. The two are then sandwiched between glass sheets and subjected to a 5 kg load for 1 hour. The coloration of the filter paper is then compared using the GB250 gray scale.

[0189] The light color fastness and light test conditions of the polymer hydrolysis resistant composite carpet are as follows: irradiance: 1.20W / m 2 @420nm, black mark temperature: 100℃, chamber temperature: 65℃, relative humidity: 20%RH, test time: 195h, total irradiation: 840KJ / m 2 ;

[0190] The color fastness grade test standard for the polymer hydrolysis-resistant composite carpet after detergent and gasoline resistance testing is "QCT 216-2019 7.10". The test conditions are: after soaking the polymer hydrolysis-resistant composite carpet with a diameter of 5 cm in neutral detergent and 120# solvent gasoline, respectively, drying or wiping at room temperature until all volatilization occurs, the color fastness is compared;

[0191] The color fastness and coloration degree are rated from 1 to 5, with 1 representing the worst color fastness and 5 representing the best color fastness.

[0192] The wear lap test conditions of the polymer hydrolysis-resistant composite carpet are as follows: a speed of 70 rpm, a load of 1000 g, and an H-18 grinding wheel.

[0193] The number of holes in the hydrophobic fiber bundle in the present invention corresponds to the number of holes in the spinneret, and the number of holes in the hydrophobic fiber bundle is the number of fiber filaments in the fiber bundle.

[0194] Based on the above, it can be seen that the polymer hydrolysis-resistant composite carpet of the present invention has a wide range of applications, low cost, and extremely high market prospects.

[0195] 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 polymer hydrolysis-resistant composite carpet, characterized in that: The polymer hydrolysis-resistant composite carpet comprises, from bottom to top, a base layer, a second support layer, a reinforcement layer, a first support layer, an adhesive layer, a base fabric layer, and a hydrophobic pile layer. The hydrophobic pile layer is formed by melting polyamide 6, a hydrophobic organosilicon material 1, a compatibilizer 1, and a masterbatch, and spinning them into a hydrophobic fiber bundle, which is then tufted onto the base fabric layer using a tufting machine. A water-based polyurethane foam latex mixed with a second hydrophobic organosilicon material 2 and a second compatibilizer is then applied to the bottom of the base fabric layer to form the adhesive layer, which has a water contact angle of 100-105°. The first support layer, the reinforcement layer, the second support layer, and the base layer are then sequentially composited to produce the polymer hydrolysis-resistant composite carpet. The first compatibilizer is maleic anhydride grafted polyamide; The first organosilicon material is a polyester modified organosilicon resin; The second compatibilizer is maleic anhydride grafted polyolefin elastomer; The second organosilicon material is polyester modified organosilicon resin; The mass ratio of the polyamide 6, the compatibilizer 1, the silicone material 1 and the masterbatch is (80:5:8:2)-(80:8:10:3); The heat-resistant dimensional stability of the polymer hydrolysis-resistant composite carpet is 0.51-0.72% in the warp direction and 0.57-0.78% in the weft direction. The water-immersion dimensional stability is 0.57-0.76% in the warp direction and 0.62-0.72% in the weft direction. The polymer hydrolysis-resistant composite carpet has a water immersion color fastness of 4.5-5, a light color fastness of ≥4, and a color fastness after detergent and gasoline testing of ≥4; The polymer hydrolysis-resistant composite carpet has a tuft pull-out force of 21-25N, a tuft pull-out force of 20-25N after being immersed in water, a wear-resistant circle number of ≥2900 circles without leakage, and a peeling force of 28-34N.

2. The polymer hydrolysis-resistant composite carpet according to claim 1, characterized in that: The polymer hydrolysis-resistant composite carpet has a thickness of 10-14 mm, a pile height of 3-5 mm, and a pile head shape of cut pile.

3. A method for preparing the polymer hydrolysis-resistant composite carpet according to any one of claims 1 to 2, characterized in that: The following steps are involved: Step 1, adding polyamide 6, a compatibilizer 1, an organosilicon material 1 and a masterbatch into a high-speed mixer and stirring and mixing to obtain a mixture, extruding the mixture through a screw extruder for spinning, the materials are melt-blended in the screw extruder and then spun through a spinneret, and rapidly air-cooled to obtain hydrophobic fiber filaments; Step 2: oiling the hydrophobic fiber filaments, performing primary stretching on the oiled hydrophobic fiber filaments, and then performing secondary stretching on the stretched hydrophobic fiber filaments; then jet puffing the stretched hydrophobic fiber filaments, cooling them with a cooling roller, knotting the hydrophobic fiber filaments in a spinning net, and winding them with a winder to obtain a hydrophobic fiber bundle; Step 3: providing a non-woven base fabric, and tufting the hydrophobic fiber bundle onto the non-woven base fabric to obtain a hydrophobic pile layer and a base fabric layer; Step 4: mixing the waterborne polyurethane foam latex, the second compatibilizer and the second organosilicon material, and applying the mixture to the bottom of the base fabric layer, and drying the mixture to obtain an adhesive layer; Step 5: After bonding the polyethylene-polyamide-polyethylene film with a coating adhesive at the bottom of the adhesive layer, bonding the needle-punched base felt with a coating adhesive is continued, and after cooling, a first support layer and a reinforcing layer are obtained; after bonding the polyethylene-polyamide-polyethylene film with a coating adhesive at the bottom of the reinforcing layer, bonding the non-woven base fabric with a coating adhesive is continued, and after cooling, a second support layer and a bottom layer are obtained; and finally, the polymer hydrolysis-resistant composite carpet is obtained.

4. The preparation method according to claim 3, characterized in that The processing temperature of the screw extruder in step 1 is 220-260°C, which is divided into four temperature zones, wherein the temperature of the first temperature zone is 220-230°C, the temperature of the second temperature zone is 240-250°C, the temperature of the third temperature zone is 250-260°C, and the temperature of the fourth temperature zone is 240-250°C.

5. The preparation method according to claim 3, characterized in that The type of oil applied in step 2 is monohydroxy silicone oil, and the oil application rate is 0.6-0.8%.

6. The preparation method according to claim 3, characterized in that The needle pitch of the tufting in step 3 is 1 / 10 or 5 / 64, the weft knitting density is 39.37 needles / cm or 50.39 needles / cm, the warp knitting density is 50-60 needles / cm, the needling depth is 5-6mm, and the needle frequency is 800-1000rpm.

7. The preparation method according to claim 3, characterized in that The mass ratio of the waterborne polyurethane foam latex, the second compatibilizer and the second organosilicon material in step 4 is (4:1:1)-(4:1:2).

8. An application of the polymer hydrolysis-resistant composite carpet according to any one of claims 1 to 2, characterized in that: The polymer hydrolysis-resistant composite carpet is applied to automobile carpets.

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