Automobile carpet and method of making same

Abstract

The application discloses a kind of automobile carpet and preparation method thereof, belong to the technical field of automotive interior parts.The application is used to solve the technical problems of the complex structure of the automobile carpet disclosed in the prior art, the complicated processing technology, the poor degradability and recyclability of the PU foam layer provided in the automobile carpet.A kind of preparation method of automobile carpet, comprising the following steps: S1, padding material and high-solidity EVA material are evenly laid on the base cloth in turn, and the base cloth is flocked to produce tufted carpet blank;Hot melt adhesive is placed between high-solidity EVA material and tufted carpet blank to obtain composite carpet;S2, the composite carpet is placed in a hot bonding machine for bonding, and naturally cooled to room temperature, which is the prepared automobile carpet.The automobile carpet prepared by the application has the advantages of simplified preparation process, good degradability of the prepared PU foam layer, good mechanical properties and thermal stability.

Description

Technical Field

[0001] This invention relates to the field of automotive interior parts technology, specifically to an automotive carpet and its preparation method. Background Technology

[0002] With the significant improvement in people's living standards, cars have become the most common means of transportation. As a soft flooring material, carpets, compared to traditional flooring materials such as wood flooring and tiles, not only have advantages such as aesthetics and cushioning against impacts, but also offer benefits like sound insulation, dust absorption, and improved indoor air quality, leading to their widespread use worldwide. However, automotive interior components use a large amount of non-metallic materials and adhesives. These non-metallic materials release significant amounts of organic matter during use, seriously affecting the air quality inside the vehicle. As a major component of the car's interior, automotive carpets are exposed over a large area in the passenger compartment, directly impacting the odor inside the car.

[0003] Patent application CN115107340A discloses an automotive carpet, its preparation method, and its application. The automotive carpet comprises a PE film, a PET carpet surface, an EVA layer, a spunlace fabric, and a PU foam layer, stacked sequentially. The EVA layer raw materials include POE, modified polyethylene, dolomite, talc, etc.; the PU foam layer comprises component A and component B. Component A includes low-emission polyether polyol, silicone oil, etc., and component B is isocyanate. Adjusting the content of components A and B in the PU foam layer reduces the odor and VOC levels of the automotive carpet. However, the poor degradability of components A and B in the aforementioned PU foam layer leads to poor recyclability. Furthermore, the automotive carpets disclosed in the prior art have complex structures and intricate processing techniques. In addition, improving the mechanical properties and thermal stability of the prepared automotive carpet is also a pressing technical problem that needs to be solved.

[0004] To address this technical deficiency, a solution is proposed. Summary of the Invention

[0005] The purpose of this invention is to provide an automotive carpet and its preparation method, which solves the technical problems of complex structure and complicated processing technology of automotive carpets disclosed in the prior art, as well as the poor degradability and recyclability of the PU foam layer in automotive carpets.

[0006] The objective of this invention can be achieved through the following technical solutions:

[0007] A method for preparing an automotive carpet includes the following steps:

[0008] S1. The filler and high-solids EVA material are evenly laid on the base fabric in sequence, and the base fabric is then flocked to produce a tufted blanket; hot melt adhesive is then placed between the high-solids EVA material and the tufted blanket to obtain a composite blanket.

[0009] S2. The composite blanket is bonded in a heat bonding machine and naturally cooled to room temperature to obtain the prepared automotive carpet.

[0010] Furthermore, the preparation method of the high-solidity EVA material includes the following steps:

[0011] A1, EVA material and NaOH powder are added together into a mixer and mixed at 100-120℃ for 2-4 hours. The mixture is then discharged to obtain saponified EVA material. The saponified EVA material and maleic anhydride are added to a mixer and heated to melt at a temperature of 180-200℃ for 20-30 minutes to prepare unsaturated EVA material.

[0012] EVA material is saponified with NaOH to obtain saponified EVA material; the saponified EVA material is then melt copolymerized and grafted with maleic anhydride to prepare unsaturated EVA material, as shown in the following reaction formula:

[0013] A2, propyltrichlorosilane, allyl bromide and organic solvent are added to a polymerization reactor, followed by rare earth metals. The mixture is stirred and mixed thoroughly to obtain a reaction system. The reaction system is reacted at 25-30℃ for 2-3 hours to obtain the product. The organic solvent is removed by distillation of the product, and the organic liquid phase allylsilane is collected.

[0014] Using rare earth metal Ln as a catalyst, propyltrichlorosilane and allyl bromide undergo a nucleophilic substitution reaction to prepare an allylsilane organic liquid phase, as shown in the following reaction formula:

[0015] A3. Unsaturated EVA material, toluene, and organic liquid phase allylsilane are mixed to obtain a reaction system; 1-3% wt potassium persulfate solution is added to the reaction system, and the reaction is carried out at 70-80℃ for 4-6 hours. Toluene is removed by rotary evaporation, and the solid is collected as the prepared high-solids EVA material.

[0016] Using toluene as a solvent and potassium persulfate as an initiator, unsaturated EVA material undergoes a free radical addition polymerization reaction with an organic liquid phase allylsilane, resulting in the synthesized high-solids EVA material.

[0017] Furthermore, in step A1, the weight ratio of EVA material to NaOH powder is 100:1-2, and the weight ratio of saponified EVA material to maleic anhydride is 101-102:5-10.

[0018] Furthermore, in step A2, the ratio of propyltrichlorosilane, allyl bromide, organic solvent, and rare earth metal is 6.5-13 mL: 18-24 g: 120-150 mL: 0.3-0.5 g.

[0019] Further, in step A3, the weight ratio of unsaturated EVA material, toluene, organic liquid phase allylsilane and potassium persulfate solution is 20-30:110-130:30-40:10-20, the rotary evaporation pressure is 5-10 kPa and the rotary evaporation temperature is 45-50℃.

[0020] Furthermore, the method for preparing the filler includes the following steps:

[0021] B1. Epoxidized soybean oil, deionized water and tert-butanol are mixed to obtain a modified solution; terminal amino polyether is reacted with the modified solution to synthesize the product;

[0022] B2. The product is rotary evaporated at 75-80℃ and -0.1~-0.2MPa for 1-1.5h to obtain a viscous organic liquid, which is the synthesized polyether polyol.

[0023] A nucleophilic ring-opening addition reaction is carried out between amino-terminated polyether and epoxidized soybean oil to synthesize polyether polyol.

[0024] B3. Mix polyether polyol, foam stabilizer, crosslinking agent, catalyst and deionized water evenly to obtain component A; mix toluene diisocyanate and diphenylmethane diisocyanate evenly to obtain component B; mix component A and component B to obtain reactant; mature the reactant to prepare filler.

[0025] The polyurethane polymer formed by reacting polyether polyol, toluene diisocyanate, diphenylmethane diisocyanate and related additives is the filler prepared.

[0026] Further, in step B1, the weight ratio of epoxidized soybean oil, deionized water and tert-butanol is 100-120:20-30:40-50, and the weight ratio of terminal amino polyether and modified liquid is 50-80:10-20.

[0027] Further, in step B3, the weight ratio of polyether polyol, foam stabilizer, crosslinking agent, catalyst and deionized water is 70-80:0.5-1.5:1-3:0.2-0.3:5-10, and the mass ratio of toluene diisocyanate and diphenylmethane diisocyanate is 1:1; the maturation temperature of the reactants is 55-65℃, and the maturation time is 12-24h.

[0028] Furthermore, in step S1, the thickness of the filler is 10-20 mm, and the thickness of the high-solids EVA material is 20-30 mm; the amount of hot melt adhesive applied is 260-300 g / m². 2 In step S2, the hot bonding speed is 5-6 cm / s, the hot bonding temperature is 125-135℃, the hot bonding time is 80-100s, and the hot bonding pressure is 0.06-0.075 MPa.

[0029] As another aspect of the present invention, an automotive carpet is prepared by a method for preparing an automotive carpet.

[0030] The present invention has the following beneficial effects:

[0031] 1. The automotive carpet structure prepared by this invention, in addition to the bottom and tufted core, also includes a filling layer and a high-solids EVA material layer, and hot melt adhesive is used to connect and composite the layers. The EVA material layer in the automotive carpet has high density and thermosetting properties, and after molding, it can maintain its shape and has good sound insulation. This invention introduces unsaturated functional groups into the EVA material through sodium hydroxide saponification and maleic anhydride melt grafting reaction. This allows for the introduction of allyl silane into the EVA material. The high-solids EVA material layer prepared by this invention contains silicon, multi-branched carbon chains, and polar functional groups, thereby improving the thermal stability of the prepared automotive carpet and its compatibility with other functional layers.

[0032] 2. The filler in the automotive carpet prepared by this invention is a polyurethane foam material. Compared to the polyol monomers used in conventional synthetic polyurethane, this invention uses epoxidized soybean oil-modified terminal amino polyether as the polyether polyol. Compared to conventional polyurethane foam materials, the filler prepared by this invention has the advantages of being environmentally friendly, having increased molecular weight and polar functional groups, thereby enabling the polyether polyol designed and synthesized by this invention to reduce the odor of the filler, reduce fogging and volatility. The automotive carpet with a composite structure prepared by this invention has the advantages of low odor, good mechanical properties, and good thermal stability. Detailed Implementation

[0033] The technical solution of the present invention will be clearly and completely described below with reference to the embodiments. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present invention.

[0034] The EVA material used in Examples 1-3 of this invention was purchased from Suzhou Chengyide Plastics Co., Ltd., with brand name V5210J, and the VA content was 95%wt. The epoxidized soybean oil used in Examples 4-6 of this invention was purchased from Guangzhou Suixin Chemical Co., Ltd., with an acid value of 0.58 and an iodine value of 2.69. The foam stabilizer used in Examples 4-6 of this invention was purchased from Tongxiang Haotian Chemical Co., Ltd., with model name KD-550 and item number 55. The amino-terminated polyether used in Examples 4-6 of this invention was specifically amino-terminated polyether D400, purchased from Shandong Lierming Trading Co., Ltd. The hot melt adhesive used in Examples 7-9 of this invention was purchased from Minli New Materials Guangzhou Co., Ltd., with model name 7117. Example 1

[0035] This embodiment provides a method for preparing a high-solids EVA material for automotive carpets, including the following steps:

[0036] A1. By weight, 100 parts of EVA material and 1 part of NaOH powder were added to a mixer. The mixer temperature was set to 120℃, the mixer speed to 50 r / min, and the mixing time to 2 h. The material was then discharged to obtain saponified EVA material. By weight, 101 parts of saponified EVA material and 5 parts of maleic anhydride were added to a mixer and heated to melt for a grafting reaction. The melting temperature was set to 180℃ and the melting time to 20 min to prepare unsaturated EVA material.

[0037] A2. A 250 mL polymerization reactor was selected. The air in the reactor was replaced with inert nitrogen gas. 6.5 mL of propyltrichlorosilane, 18 g of allyl bromide and 120 mL of benzene were added to the 250 mL polymerization reactor, followed by 0.3 g of rare earth metal Ln. The mixture was stirred at 300 r / min until it was homogeneous to obtain the reaction system. The reaction system was reacted at 25 °C for 2 h to obtain the product. The product was filtered and the organic solvent benzene was removed by distillation at 82 °C. The organic liquid phase allyl silane was collected.

[0038] A3. According to the weight, add 20 parts of unsaturated EVA material, 110 parts of toluene, and 3 parts of organic liquid phase allylsilane to a reactor equipped with a stirrer, thermometer, dropping device, and reflux cooler, mix well, and obtain a reaction system; add 10 parts of 1%wt potassium persulfate solution to the reactor through the dropping device, and react at a constant temperature of 70℃ for 4 hours, then remove the toluene solution by rotary evaporation at a pressure of 5 kPa and a temperature of 45℃, and collect the solid as the prepared high-solids EVA material. Example 2

[0039] This embodiment provides a method for preparing a high-solids EVA material for automotive carpets, including the following steps:

[0040] A1. By weight, 100 parts of EVA material and 1.5 parts of NaOH powder were added to a mixer. The mixer temperature was set to 110℃, the mixer speed to 55 r / min, and the mixing time to 3 h. The material was then discharged to obtain saponified EVA material. By weight, 102 parts of saponified EVA material and 8 parts of maleic anhydride were added to a mixer and heated to melt for a grafting reaction. The melting temperature was set to 190℃ and the melting time to 22 min to prepare unsaturated EVA material.

[0041] A2. A 250 mL polymerization reactor was selected. The air in the reactor was replaced with inert nitrogen gas. 8.5 mL of propyltrichlorosilane, 22 g of allyl bromide and 130 mL of benzene were added to the 250 mL polymerization reactor, followed by 0.4 g of rare earth metal Ln. The mixture was stirred at 450 r / min until it was homogeneous to obtain the reaction system. The reaction system was reacted at 26 °C for 2.5 h to obtain the product. The product was filtered and the organic solvent benzene was removed by distillation at 83 °C. The organic liquid phase allyl silane was collected.

[0042] A3. According to the weight, add 26 parts of unsaturated EVA material, 120 parts of toluene, and 35 parts of organic liquid phase allylsilane to a reactor equipped with a stirrer, thermometer, dropping device, and reflux cooler, mix well, and obtain a reaction system; add 15 parts of 2%wt potassium persulfate solution to the reactor through the dropping device, and react at a constant temperature of 77℃ for 5 hours, then remove the toluene solution by rotary evaporation at a pressure of 8 kPa and a temperature of 48℃, and collect the solid as the prepared high-solids EVA material. Example 3

[0043] This embodiment provides a method for preparing a high-solids EVA material for automotive carpets, including the following steps:

[0044] A1. By weight, 100 parts of EVA material and 2 parts of NaOH powder were added to a mixer. The mixer temperature was set to 100℃, the mixer speed was set to 60 r / min, and the mixing time was set to 4 h. The material was then discharged to obtain saponified EVA material. By weight, 102 parts of saponified EVA material and 10 parts of maleic anhydride were added to a mixer and heated to melt for a grafting reaction. The heating and melting temperature was set to 200℃ and the heating and melting time was set to 30 min to prepare unsaturated EVA material.

[0045] A2. Select a 250 mL polymerization reactor. Replace the air in the reactor with inert nitrogen gas. Add 13 mL of propyltrichlorosilane, 24 g of allyl bromide, and 150 mL of benzene to the 250 mL polymerization reactor. Then add 0.5 g of rare earth metal Ln. Stir at 500 r / min until the mixture is homogeneous to obtain the reaction system. React the reaction system at 30 °C for 3 h to obtain the product. Filter the product and distill at 85 °C to remove the organic solvent benzene, collecting the organic liquid phase allyl silane.

[0046] A3. According to the weight, add 30 parts of unsaturated EVA material, 130 parts of toluene, and 40 parts of organic liquid phase allylsilane to a reaction vessel equipped with a stirrer, thermometer, dropping device, and reflux cooler, mix well, and obtain a reaction system; add 20 parts of 3%wt potassium persulfate solution to the reaction vessel through the dropping device, and react at a constant temperature of 80℃ for 6 hours, then remove the toluene solution by rotary evaporation at a pressure of 10 kPa and a temperature of 50℃, and collect the solid as the prepared high-solids EVA material. Example 4

[0047] This embodiment provides a method for preparing a filler material for automotive carpets, including the following steps:

[0048] B1. By weight, 100 parts of epoxidized soybean oil, 20 parts of deionized water, and 40 parts of tert-butanol are added to a single-necked round-bottom flask and mixed thoroughly to obtain a modified liquid. A stainless steel reactor is selected. The reactor structure, from top to bottom, consists of a raw material mixing chamber, a catalyst loading zone, a packing zone, and a product outlet. By weight, 50 parts of terminal amino polyether and 10 parts of the modified liquid are added to the raw material mixing chamber. Zinc acetylacetone is loaded into the catalyst loading zone. The reaction is carried out at 90°C for 5 hours, and the product is collected from the product outlet.

[0049] B2. The product is rotary evaporated at 75℃ and -0.1MPa for 1 hour until all deionized water and tert-butanol are evaporated. The resulting viscous organic liquid is the synthesized polyether polyol.

[0050] B3. By weight, 70 parts of polyether polyol, 0.5 parts of foam stabilizer, 1 part of crosslinking agent glycerol, 0.2 parts of catalyst triethylenediamine, and 5 parts of deionized water are stirred evenly to obtain component A; toluene diisocyanate and diphenylmethane diisocyanate are mixed at a mass ratio of 1:1 to obtain component B. Component A and component B are mixed at a mass ratio of 100:30 and stirred rapidly for 5 seconds to obtain the reactant; the reactant is poured into a mold at 55°C and cured for 12 hours to prepare the filler. Example 5

[0051] This embodiment provides a method for preparing a filler material for automotive carpets, including the following steps:

[0052] B1. By weight, 110 parts of epoxidized soybean oil, 25 parts of deionized water, and 46 parts of tert-butanol were added to a single-necked round-bottom flask and mixed thoroughly to obtain a modified liquid. A stainless steel reactor was selected. The reactor structure, from top to bottom, consisted of a raw material mixing chamber, a catalyst loading zone, a packing zone, and a product outlet. By weight, 60 parts of terminal amino polyether and 15 parts of the modified liquid were added to the raw material mixing chamber. Zinc acetylacetone was loaded into the catalyst loading zone. The reaction was carried out at 95°C for 5.5 hours, and the product was collected from the product outlet.

[0053] B2. The product is rotary evaporated at 78℃ and -0.15MPa for 1.2h until all deionized water and tert-butanol are evaporated. The resulting viscous organic liquid is the synthesized polyether polyol.

[0054] B3. By weight, 75 parts of polyether polyol, 1 part of foam stabilizer, 2 parts of crosslinking agent glycerol, 0.25 parts of catalyst triethylenediamine, and 8 parts of deionized water are stirred evenly to obtain component A; toluene diisocyanate and diphenylmethane diisocyanate are mixed at a mass ratio of 1:1 to obtain component B; component A and component B are mixed at a mass ratio of 100:33 and stirred rapidly for 8 seconds to obtain the reactant. The reactant is poured into a mold at 60°C and cured for 18 hours to prepare the filler. Example 6

[0055] This embodiment provides a method for preparing a filler material for automotive carpets, including the following steps:

[0056] B1. By weight, 120 parts of epoxidized soybean oil, 30 parts of deionized water, and 50 parts of tert-butanol were added to a single-necked round-bottom flask and mixed thoroughly to obtain a modified liquid. A stainless steel reactor was selected. The reactor structure, from top to bottom, consisted of a raw material mixing chamber, a catalyst loading zone, a packing zone, and a product outlet. By weight, 80 parts of terminal amino polyether and 20 parts of the modified liquid were added to the raw material mixing chamber. Zinc acetylacetone was loaded into the catalyst loading zone. The reaction was carried out at 100°C for 6 hours, and the product was collected from the product outlet.

[0057] B2. The product is rotary evaporated at 80℃ and -0.2MPa for 1.5h until all deionized water and tert-butanol are evaporated. The resulting viscous organic liquid is the synthesized polyether polyol.

[0058] B3. By weight, 80 parts of polyether polyol, 1.5 parts of foam stabilizer, 3 parts of crosslinking agent glycerol, 0.3 parts of catalyst triethylenediamine, and 10 parts of deionized water are stirred evenly to obtain mixture A. Toluene diisocyanate and diphenylmethane diisocyanate are mixed at a mass ratio of 1:1 to obtain mixture B. Mix mixture A and mixture B at a mass ratio of 100:40 and stir rapidly for 10 seconds to obtain the reactant. The reactant is poured into a mold at 65°C and cured for 24 hours to prepare the filler. Example 7

[0059] This embodiment provides a method for preparing an automotive carpet, including the following steps:

[0060] S1. An automotive carpet, from top to bottom, comprises a base fabric, a filling material, a high-solids EVA material, and a tufted carpet. First, the filling material prepared in Example 4 and the high-solids EVA material prepared in Example 1 are laid evenly on the base fabric, with the filling material having a thickness of 10 mm and the high-solids EVA material having a thickness of 20 mm. Then, the base fabric is flocked to produce a tufted carpet. Hot melt adhesive is then placed between the high-solids EVA material and the tufted carpet, with a hot melt adhesive application rate of 260 g / m². 2 The resulting composite blanket fabric is obtained.

[0061] S2. The composite carpet is bonded in a heat bonding machine to finally obtain the automotive carpet. The speed of the heat bonding machine is 6 cm / s, the heat bonding temperature is 125℃, the heat bonding time is 80s, and the heat bonding pressure is 0.06MPa. After the heat bonding process is completed, the tufted carpet is placed at room temperature to cool naturally, and the automotive carpet is finally obtained. Example 8

[0062] This embodiment provides a method for preparing an automotive carpet, including the following steps:

[0063] S1. An automotive carpet, from top to bottom, comprises a base fabric, a filling material, a high-solids EVA material, and a tufted carpet. First, the filling material prepared in Example 5 and the high-solids EVA material prepared in Example 2 are sequentially and evenly laid on the base fabric, with the filling material having a laying thickness of 15mm and the high-solids EVA material having a laying thickness of 25mm. Then, the base fabric is flocked to produce a tufted carpet. Hot melt adhesive is then placed between the high-solids EVA material and the tufted carpet, with a hot melt adhesive application rate of 280g / m². 2 The resulting composite blanket fabric is obtained.

[0064] S2. The composite carpet is bonded in a heat bonding machine to finally obtain the automotive carpet. The speed of the heat bonding machine is 5.5 cm / s, the heat bonding temperature is 130℃, the heat bonding time is 90s, and the heat bonding pressure is 0.07MPa. After the heat bonding process is completed, the tufted carpet is placed at room temperature to cool naturally, and the automotive carpet is finally obtained. Example 9

[0065] This embodiment provides a method for preparing an automotive carpet, including the following steps:

[0066] S1. An automotive carpet, from top to bottom, comprises a base fabric, a filling material, a high-solids EVA material, and a tufted carpet. First, the filling material prepared in Example 6 and the high-solids EVA material prepared in Example 3 are sequentially and evenly laid on the base fabric, with the filling material having a laying thickness of 20 mm and the high-solids EVA material having a laying thickness of 30 mm. Then, the base fabric is flocked to produce a tufted carpet. Hot melt adhesive is then placed between the high-solids EVA material and the tufted carpet, with a hot melt adhesive application rate of 300 g / m². 2 The resulting composite blanket fabric is obtained.

[0067] S2. The composite carpet is bonded in a heat bonding machine to finally obtain the car carpet. The heat bonding machine speed is 5cm / s, the heat bonding temperature is 135℃, the heat bonding time is 100s, and the heat bonding pressure is 0.075MPa. After the heat bonding process is completed, the tufted carpet is placed at room temperature to cool naturally, and the car carpet is finally obtained.

[0068] Comparative Example 1

[0069] The difference between this comparative example and Example 9 is that, in preparing the high-solids EVA material, steps A2 and A3 are omitted, and an equal mass of unsaturated EVA material is used to replace the high-solids EVA material.

[0070] Comparative Example 2

[0071] The difference between this comparative example and Example 9 is that step A2 is omitted when preparing the high-solidity EVA material; and in step A3, an equal mass of allyl bromide is used to replace the synthesized organic liquid phase allylsilane.

[0072] Comparative Example 3

[0073] The difference between this comparative example and Example 9 lies in the B1 step during the preparation of the filler, as detailed below:

[0074] B1. Select a stainless steel reactor. The reactor structure, from top to bottom, consists of a raw material mixing chamber, a catalyst loading zone, a packing zone, and a product outlet. By weight, add 50 parts of terminal amino polyether and 10 parts of tert-butanol to the raw material mixing chamber. The catalyst loading zone is filled with zinc acetylacetone. React at 80°C for 5 hours and collect the product from the product outlet.

[0075] Performance testing:

[0076] 1. The car carpets prepared in Examples 7-9 and Comparative Examples 1-3 of this invention were cut into 1cm × 1cm square pieces. These square pieces were placed in four odor bottles, the caps were tightened, and the four odor bottles were placed in an oven and aged at 80°C for 2 hours. Three evaluators assessed the odor levels of the odor bottles. The odor level classification criteria were as follows: Level 1, barely noticeable; Level 2, noticeable but not pungent; Level 3, noticeable but not pungent; Level 4, pungent; Level 5, very pungent; Level 6, unbearable.

[0077] 2. In accordance with QB / T1090-2001 "Test Method for Pull-out Force of Carpet Tufts", pull-out force tests were conducted on the automotive carpets prepared in Examples 7-9 and Comparative Examples 1-3 in sequence.

[0078] 3. The automotive carpets prepared in Examples 7-9 and Comparative Examples 1-3 were cut sequentially to a total weight of 5 mg. The automotive carpets prepared in Examples 7-9 and Comparative Examples 1-3 were then heated from 45°C to 600°C at a heating rate of 10°C / min, while the carpets were placed in a nitrogen atmosphere during the heating process. The temperature at which the weight loss rate was maximized was measured.

[0079] 4. According to GB / T3819-1997 "Determination of the recovery performance of textile creases - Recovery angle method", the crease recovery angles of the automotive carpets prepared in Examples 7-9 and Comparative Examples 1-3 were tested in sequence.

[0080]

[0081] Data Analysis: The automotive carpets prepared in Examples 7-9 of this invention all have low odor levels and low odor concentrations. In Comparative Example 3, an equal mass of tert-butanol was used to replace the modifying liquid when preparing the filler. In Examples 7-9, tert-butanol was modified with epoxidized soybean oil, utilizing the epoxy groups contained in epoxidized soybean oil as functional groups to react with terminal amino polyethers, thereby synthesizing polyether polyols. The polyether polyol synthesized in Comparative Example 3 has a low relative molecular mass, few polar functional groups, and high volatility, resulting in automotive carpets prepared in Comparative Example 3 having higher odor level values ​​and higher odor concentrations.

[0082] In Comparative Example 1, unsaturated EVA material of equal mass was used to replace high-solids EVA material; the organic liquid phase allylsilane was not added to the prepared unsaturated EVA material, resulting in a lower degree of crosslinking and a lower number of polar functional groups. This was reflected in the reduced thermal stability of the car carpet prepared in Comparative Example 1, which manifested as a decrease in the temperature at which the car carpet prepared in Comparative Example 1 had the maximum weight loss and a decrease in wrinkle resistance.

[0083] In Comparative Example 2, an equal mass of allyl bromide was used to replace the synthesized organic liquid phase allyl silane. Compared to allyl silane, the allyl bromide added to the EVA material lacked silicon and had a shorter chain length, resulting in a decrease in mechanical properties and a reduction in pull-out force.

[0084] The above description is merely an example and illustration of the structure of the present invention. Those skilled in the art can make various modifications or additions to the specific embodiments described, or use similar methods to replace them, as long as they do not deviate from the structure of the invention or exceed the scope defined in the claims, all of which should fall within the protection scope of the present invention.

[0085] In the description of this specification, references to terms such as "an embodiment," "example," "specific example," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of the invention. In this specification, illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

[0086] The preferred embodiments of the present invention disclosed above are merely illustrative of the invention. These preferred embodiments do not exhaustively describe all details, nor do they limit the invention to specific implementations. Clearly, many modifications and variations can be made based on the content of this specification. This specification selects and specifically describes these embodiments to better explain the principles and practical applications of the invention, thereby enabling those skilled in the art to better understand and utilize the invention. The invention is limited only by the claims and their full scope and equivalents.

Claims

1. A method for preparing an automotive carpet, characterized in that, Includes the following steps: S1. The filler and high-solids EVA material are laid evenly on the base fabric in sequence. The base fabric is flocked to produce a tufted blanket. Then, hot melt adhesive is placed between the high-solids EVA material and the tufted blanket to obtain a composite blanket. S2. The composite blanket is bonded in a heat bonding machine and naturally cooled to room temperature to obtain the prepared automotive carpet. The preparation method of the high-solidity EVA material includes the following steps: A1, EVA material and NaOH powder are put into a mixer and mixed at 100-120℃ for 2-4 hours. The mixture is then discharged to obtain saponified EVA material. The saponified EVA material and maleic anhydride are added to the mixer and heated to melt at 180-200℃ for 20-30 minutes to prepare unsaturated EVA material. A2, propyltrichlorosilane, allyl bromide and organic solvent are added to a polymerization reactor, followed by rare earth metals. The mixture is stirred and mixed thoroughly to obtain a reaction system. The reaction system is reacted at 25-30℃ for 2-3 hours to obtain the product. The organic solvent is removed by distillation of the product, and the organic liquid phase allylsilane is collected. A3. Unsaturated EVA material, toluene, and organic liquid phase allylsilane are mixed to obtain a reaction system; 1-3% wt potassium persulfate solution is added to the reaction system, and the reaction is carried out at 70-80℃ for 4-6 hours. Toluene is removed by rotary evaporation, and the solid is collected as the prepared high-solids EVA material.

2. The method for preparing an automotive carpet according to claim 1, characterized in that, In step A1, the weight ratio of EVA material to NaOH powder is 100:1-2, and the weight ratio of saponified EVA material to maleic anhydride is 101-102:5-10.

3. The method for preparing an automotive carpet according to claim 1, characterized in that, In step A2, the ratio of propyltrichlorosilane, allyl bromide, organic solvent and rare earth metal is 6.5-13 mL: 18-24 g: 120-150 mL: 0.3-0.5 g.

4. The method for preparing an automotive carpet according to claim 1, characterized in that, In step A3, the weight ratio of unsaturated EVA material, toluene, organic liquid phase allylsilane and potassium persulfate solution is 20-30:110-130:30-40:10-20, the rotary evaporation pressure is 5-10 kPa and the rotary evaporation temperature is 45-50℃.

5. The method for preparing an automotive carpet according to claim 1, characterized in that, The method for preparing the filler includes the following steps: B1. Epoxidized soybean oil, deionized water and tert-butanol are mixed to obtain a modified solution; terminal amino polyether is reacted with the modified solution to synthesize the product; B2. The product is rotary evaporated at 75-80℃ and -0.1~-0.2MPa for 1-1.5h to obtain a viscous organic liquid, which is the synthesized polyether polyol. B3. Mix polyether polyol, foam stabilizer, crosslinking agent, catalyst and deionized water evenly to obtain component A; mix toluene diisocyanate and diphenylmethane diisocyanate evenly to obtain component B; mix component A and component B to obtain reactant; mature the reactant to prepare filler.

6. The method for preparing an automotive carpet according to claim 5, characterized in that, In step B1, the weight ratio of epoxidized soybean oil, deionized water and tert-butanol is 100-120:20-30:40-50, and the weight ratio of terminal amino polyether and modified liquid is 50-80:10-20.

7. The method for preparing an automotive carpet according to claim 5, characterized in that, In step B3, the weight ratio of polyether polyol, foam stabilizer, crosslinking agent, catalyst, and deionized water is 70-80: The mass ratio of toluene diisocyanate to diphenylmethane diisocyanate is 1:1 (0.5-1.5:1-3:0.2-0.3:5-10). The maturation temperature of the reactants is 55-65℃ and the maturation time is 12-24h.

8. The method for preparing an automotive carpet according to claim 1, characterized in that, In step S1, the filler thickness is 10-20mm, and the high-solids EVA material thickness is 20-30mm; the hot melt adhesive application rate is 260-300g / m². 2 In step S2, the hot bonding speed is 5-6 cm / s, the hot bonding temperature is 125-135℃, the hot bonding time is 80-100s, and the hot bonding pressure is 0.06-0.075 MPa.

9. A car carpet, characterized in that, The car carpet is prepared using the method described in any one of claims 1-8.

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