Automotive foam carpet and method of making

Abstract

The application discloses a kind of automobile foaming carpet and preparation method, belong to the production technical field of automotive interior parts.It includes abrasion-resistant and stain-resistant surface layer, low-temperature cushioning foaming layer, sound insulation and antibacterial main foaming layer, dimensionally stable reinforcing layer and waterproof and antiskid laminated bottom layer arranged from top to bottom, each layer is integrally formed between composite, the abrasion-resistant and stain-resistant surface layer uses flame-retardant PET needle punching felt, the low-temperature cushioning foaming layer uses EVA micro-closed-cell foaming material, the sound insulation and antibacterial main foaming layer uses graphene modified polyurethane physical foaming material, the dimensionally stable reinforcing layer uses glass fiber mesh cloth, and the waterproof and antiskid laminated bottom layer uses butyl rubber microcellular material.The automobile foaming carpet of the application synergizes through five-layer light-weight composite integrated structure, and multiple automobile special properties such as high and low temperature weather resistance, high resilience, flame-retardant antibacterial, waterproof sound insulation, dimensional stability are considered, better adapt to automobile floor assembly working condition.

Description

Technical Field

[0001] This invention belongs to the field of automotive interior parts manufacturing technology, specifically relating to an automotive foam carpet that is adapted to the requirements of vehicle lightweighting, has low odor, is resistant to high and low temperatures, and is flame-retardant and sound-insulating, as well as its preparation method. Background Technology

[0002] Automotive foam carpets are functional components of automotive interiors, serving multiple purposes including covering the floor, shock absorption and sound insulation, heat insulation, slip resistance and dust prevention, and improving the in-car environment. Currently, most mainstream automotive foam carpets on the market use a PVC surface layer + PU foam composite structure, which has several technical shortcomings for the complex usage scenarios in automobiles. 1. Failure to meet environmental protection standards: Traditional carpets use chemical foaming agents, inferior plasticizers and solvent-based adhesives. Under high temperature and sun exposure, they are very likely to release harmful substances such as formaldehyde, benzene series and TVOC, producing odors in the car. They cannot meet the strict standards of low odor and low VOC, which endangers the health of drivers and passengers. 2. Poor weather resistance: Commercial vehicle operation scenarios are diverse, and the climate varies significantly in different regions. Temperature and humidity vary greatly. Traditional foamed structures are prone to brittleness at low temperatures and deformation and collapse at high temperatures. They have insufficient resilience and durability, and long-term use can easily lead to defects such as dents and peeling of the covering layer from the foam layer. 3. Insufficient overall protective performance: Ordinary carpets have a low flame retardant rating and are easily ignited and spread when exposed to open flames, posing a driving safety hazard; at the same time, they are weak in wear resistance, stain resistance, and water resistance, allowing mud and water stains to easily penetrate and breed bacteria and mold; in addition, the sound insulation and vibration reduction effect of the bottom plate is poor, and it cannot effectively block tire noise and road noise. 4. Insufficient lightweighting: Lightweight carpets have poor structural stability, are prone to stretching and deformation, and have poor sound insulation, while ordinary carpets are heavy, reducing the driving range of new energy vehicles. 5. Limited production process: Existing manufacturing processes are mostly split molding and segmented composite production, which are complicated, have low yield, cannot achieve continuous production line production, have high energy consumption, limited production capacity, and poor uniformity of product thickness and structure. Summary of the Invention

[0003] The purpose of this invention is to overcome the shortcomings of the prior art and provide an automotive foam carpet and its preparation method, so as to solve the problems of existing carpets not meeting environmental protection standards, poor weather resistance, insufficient comprehensive protective performance, insufficient lightweighting, and large limitations in production process.

[0004] To achieve the above objectives, the present invention adopts the following technical solution: In a first aspect, the present invention provides an automotive foam carpet, comprising, from top to bottom, a wear-resistant and stain-resistant surface layer, a low-temperature buffer foam layer, a sound-insulating and antibacterial main foam layer, a dimensionally stable reinforcing layer, and a waterproof and anti-slip bonding bottom layer, wherein each layer is integrally formed. The wear-resistant and stain-resistant surface layer is made of flame-retardant PET needle-punched felt, the low-temperature buffer foam layer is made of EVA micro-closed-cell foam material, the sound-insulating and antibacterial main foam layer is made of graphene-modified polyurethane physical foam material, the dimensionally stable reinforcing layer is made of fiberglass mesh cloth, and the waterproof and anti-slip bonding bottom layer is made of butyl rubber micro-foam material.

[0005] Furthermore, the thickness of the wear-resistant and stain-resistant surface layer is 1.5~1.8mm, and the basis weight of the wear-resistant and stain-resistant surface layer is 300~350g / ㎡.

[0006] Furthermore, the thickness of the low-temperature buffer foam layer is 2.0~2.5mm, and the density is 140±10kg / m³; And / or, the closed-cell rate of the EVA micro-closed-cell foam material is ≥92%; And / or, the EVA micro-closed-cell foam material comprises the following raw materials in parts by weight: 48-52 parts of POE blended modified EVA resin, 33-36 parts of heavy calcium carbonate, 1.2-1.8 parts of composite weather-resistant heat stabilizer, 1.0-1.3 parts of crosslinking agent, and 0.5-0.8 parts of low-temperature toughening agent; the EVA micro-closed-cell foam material is formed by mixing the raw materials in the above-mentioned parts by weight and using pure mechanical physical foaming.

[0007] Furthermore, the thickness of the sound-insulating and antibacterial foam layer is 3.0–3.5 mm, and the density is 100 ± 10 kg / m³. And / or, the graphene-modified polyurethane physical foaming material comprises the following raw materials in parts by weight: 64-67 parts of low-odor, high-activity polyoxypropylene ether triol, 32-35 parts of diphenylmethane diisocyanate, 0.8-1.1 parts of aqueous graphene dispersion, 1.2-1.6 parts of organosilicon low-odor foaming agent, 0.4-0.5 parts of low-VOC reactive composite tertiary amine environmentally friendly catalyst, and 2.2-2.8 parts of deionized water. The graphene-modified polyurethane physical foaming material is formed by mixing the raw materials in the above-mentioned parts by weight and then physically foaming them.

[0008] Furthermore, the thickness of the glass fiber mesh is 0.4–0.5 mm.

[0009] Furthermore, the thickness of the waterproof and anti-slip adhesive base layer is 1.0~1.2mm, and its bottom surface is provided with dotted anti-slip protrusions.

[0010] Secondly, a method for preparing automotive foam carpet includes: The surface of the flame-retardant PET needle-punched felt is activated by high-voltage corona treatment, and water-based adhesive is coated on the lower surface of the flame-retardant PET needle-punched felt to obtain a pre-treated wear-resistant and stain-resistant surface layer. The lower surface of the pretreated wear-resistant and stain-resistant surface layer is aligned and hot-pressed with the pre-made EVA micro-closed-cell foam material, and then cooled and shaped at a constant temperature to obtain a low-temperature buffer foam layer. After coating the lower surface of the low-temperature buffer foam layer with a pre-made graphene-modified polyurethane physical foaming material, and then allowing it to stand at a constant temperature, an incompletely cured sound insulation and antibacterial main foam layer is obtained. A fiberglass mesh is laid on the underside of the not fully cured sound insulation and antibacterial foam layer, and then simultaneously hot-pressed at a constant temperature to obtain a fully cured sound insulation and antibacterial foam layer and a dimensionally stable reinforcing layer. Water-based adhesive is applied to the dimensionally stable reinforcing layer, and multi-layer butyl rubber micro-foamed material is composited to obtain a waterproof and non-slip bonding bottom layer. The overall structure is then subjected to constant temperature hot pressing composite, and after complete curing by constant temperature air cooling, a five-layer integrated foamed carpet is obtained.

[0011] Furthermore, the coating amount of the water-based adhesive on the lower surface of the flame-retardant PET needle-punched felt is 100±5g / ㎡.

[0012] Furthermore, the hot-pressing temperature for aligning and hot-pressing the lower surface of the pretreated wear-resistant and stain-resistant surface layer with the pre-made EVA micro-closed-cell foam material is 150±5℃, and the hot-pressing pressure is 0.4±0.05MPa.

[0013] Furthermore, the temperature range of the overall structure for constant temperature hot pressing composite is 125–135℃, and the pressure range is 0.25–0.35MPa.

[0014] Compared with the prior art, the present invention has the following beneficial effects: 1. This invention provides a five-layer lightweight composite integrated structure carpet. Its structure, from top to bottom, includes a wear-resistant surface layer, a low-temperature buffer foam layer, a sound-insulating and antibacterial main foam layer, a dimensionally stable reinforcing layer, and a waterproof and anti-slip bonding bottom layer. The five layers work synergistically, taking into account multiple automotive-specific properties such as high and low temperature weather resistance, high resilience, flame retardancy and antibacterial properties, waterproofing and sound insulation, and dimensional stability. It exhibits excellent performance in durability, environmental friendliness, and weather resistance, with an overall resilience rate ≥68% and a sound insulation reduction of ≥30dB, effectively blocking road noise and tire noise. The surface layer is wear-resistant, stain-resistant, and easy to clean, while the bottom layer is waterproof, moisture-proof, and firmly bonded, while also possessing antibacterial and antistatic properties, preventing mold growth, static interference, and fire hazards, comprehensively improving the in-vehicle driving experience. The overall lightweight design results in a finished product weight ≤2.2kg / ㎡, reducing weight by more than 15% compared to traditional automotive foam carpets, effectively reducing vehicle weight, increasing the driving range of new energy vehicles, and aligning with the trend of lightweight vehicle development. 2. This invention provides a method for preparing carpets, with a continuous production line process. The process is simplified, and the entire process is automated and continuous. No special customized molds are required. The process is simplified, energy consumption is low, and production efficiency is increased by more than 35%. It can be promoted for industrialization. At the same time, the product consistency is good. The product thickness, size and performance are highly consistent, the yield rate is significantly improved, the production cost is greatly reduced, and it is suitable for standardized assembly of various car models. It can be used for the large-scale and standardized mass production of automotive parts. 3. The low-temperature buffer foam layer and the sound insulation and antibacterial main foam layer abandon chemical foaming agents and adopt physical foaming. Moreover, the connection between each layer uses water-based environmentally friendly adhesive instead of solvent-based adhesive. The product is formaldehyde-free, low in TVOC, and has no odor release when exposed to high temperature. The odor level and VOC content fully comply with the national standards for automotive interiors, completely solving the problem of odor pollution from car carpets. 4. The low-temperature buffer foam layer, through its low-temperature resistant modified formula and dense closed-cell structure design, can withstand alternating high and low temperature conditions from -40℃ to 85℃ for a long time. It does not crack at low temperatures, does not deform or collapse at high temperatures, has strong resilience and durability, and does not loosen or make abnormal noises during long-term driving vibrations, making it suitable for complex driving environments in various regions. Attached Figure Description

[0015] Figure 1 This is a schematic diagram of the structure of the foamed carpet of the present invention.

[0016] In the diagram, 1. Wear-resistant and stain-resistant surface layer, 2. Low-temperature buffer foam layer, 3. Sound-insulating and antibacterial main foam layer, 4. Dimensionally stable reinforcing layer, 5. Waterproof and anti-slip bonding bottom layer, 51. Anti-slip protrusion. Detailed Implementation

[0017] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings. 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 skilled in the art without creative effort are within the protection scope of the present invention.

[0018] Example 1

[0019] like Figure 1 As shown, this embodiment of the invention provides an automotive foam carpet, comprising: a wear-resistant and stain-resistant surface layer 1, a low-temperature buffer foam layer 2, a sound-insulating and antibacterial main foam layer 3, a dimensionally stable reinforcing layer 4, and a waterproof and anti-slip bonding bottom layer 5 arranged from top to bottom. The layers are integrally molded together, resulting in a lightweight, thin, and highly conformable overall structure with strong resistance to deformation, thus better adapting to automotive floor assembly conditions.

[0020] The wear-resistant and stain-resistant surface layer 1 is made of flame-retardant PET needle-punched felt with a thickness of 1.8mm and a weight of 350g / ㎡. It adopts a wear-resistant modified formula and has high wear resistance, stain resistance, easy cleaning and anti-static properties. It can effectively resist the wear of mud and sand on the soles of the feet and the penetration of stains, and avoid the accumulation of static electricity.

[0021] The low-temperature buffer foam layer 2 is made of low-temperature resistant EVA micro-closed-cell foam material with a thickness of 2.5mm, a closed-cell rate of ≥92%, and a density of 140±10kg / m³. It can adapt to the low-temperature working conditions of automobiles and does not crack in an environment of -40℃, maintaining good elasticity.

[0022] The sound insulation and antibacterial main foam layer 3 is made of graphene-modified polyurethane physical foam material with a thickness of 3.5mm and a density of 100±10kg / m³. It is the core functional layer of the carpet and has excellent sound absorption and noise reduction, heat insulation, antibacterial and anti-aging properties. It can effectively block tire noise and road noise, inhibit the growth of mold in the car, and has no odor release under high temperature conditions.

[0023] The dimensional stability reinforcement layer 4 uses ultra-thin glass fiber mesh cloth with a thickness of 0.5mm to enhance the dimensional stability of the carpet, significantly improve the overall tensile strength and dimensional stability of the carpet, prevent tensile deformation and interlayer detachment during installation and use, and ensure the assembly accuracy of the whole vehicle.

[0024] The waterproof and anti-slip bonding bottom layer 5 is made of butyl rubber micro-foamed material with a thickness of 1.2mm. The surface is evenly set with dot-shaped anti-slip protrusions 51 to improve the positional stability of the carpet after installation. It adheres to the car body panel with strong adhesion and is not easy to shift. At the same time, it has excellent waterproof and moisture-proof performance, which can block the moisture penetration of the base plate and prevent the carpet from getting moldy and the sheet metal from rusting.

[0025] The layers are bonded together to form an integral structure by water-based adhesive or hot pressing. The water-based adhesive used is an automotive-grade environmentally friendly water-based polyurethane adhesive with a solid content of 40% to 42%, which is formaldehyde-free, benzene-free, low in VOCs, odorless at high temperatures, and meets the stringent environmental standards for automotive interiors.

[0026] This invention provides a five-layer lightweight composite integrated automotive foam carpet. The five layers work synergistically, achieving an overall resilience of ≥68% and a sound insulation and noise reduction of ≥30dB, effectively blocking road and tire noise. The surface layer is wear-resistant, stain-resistant, and easy to clean, while the bottom layer is waterproof, moisture-proof, and firmly bonded. It also possesses antibacterial and antistatic properties, preventing mold growth, static interference, and fire hazards, comprehensively improving the in-vehicle ride quality. Furthermore, the overall lightweight design results in a finished product weight of ≤2.2kg / ㎡, a 15% weight reduction compared to traditional automotive foam carpets. This effectively reduces the vehicle's weight by over 90%, improving the driving range of new energy vehicles and aligning with the trend of lightweight vehicle development. Simultaneously, it provides a new raw material ratio for the foam layer. The foam layer obtained according to this ratio possesses characteristics of high and low temperature resistance and low VOCs. Through low-temperature modified formula and dense closed-cell structure design, it can withstand alternating high and low temperature conditions from -40℃ to 85℃ for extended periods. It exhibits no brittleness at low temperatures, no deformation or collapse at high temperatures, strong resilience and durability, and no loosening or abnormal noise during long-term driving vibrations, making it suitable for complex driving environments in various regions.

[0027] Example 2

[0028] This embodiment provides a method for preparing the automotive foam carpet described in Embodiment 1, comprising the following steps:

[0029] Step 1: Perform high-voltage corona activation treatment on the surface of the flame-retardant PET needle-punched felt to improve surface adhesion; uniformly coat the underside of the flame-retardant PET needle-punched felt with a layer of environmentally friendly water-based polyurethane adhesive at a coating amount of 100±5g / ㎡ to prevent peeling and delamination later, thus completing the wear-resistant and stain-resistant surface pretreatment.

[0030] Step 2: Align and hot-press the lower surface of the wear-resistant and stain-resistant surface layer with the pre-made EVA micro-closed-cell foam material, and then cool and shape it at a constant temperature. The hot-pressing temperature is 150℃ and the hot-pressing pressure is 0.4MPa. After cooling and shaping at a constant temperature, a low-temperature buffer foam layer is formed, resulting in a high-strength double-layer composite substrate.

[0031] The pre-fabricated EVA micro-closed-cell foam material is prepared by the following method: the low-temperature resistant EVA micro-closed-cell foam material comprises the following parts by weight: 50 parts of low-temperature resistant POE-modified EVA resin, 35 parts of heavy calcium carbonate, 1.6 parts of composite weather-resistant heat stabilizer, 1.2 parts of crosslinking agent, and 0.7 parts of low-temperature toughening agent. The mixture is prepared by pure mechanical physical foaming according to the above parts by weight, exhibiting excellent low-temperature toughness. Furthermore, this layer contains no chemical foaming agent, solving the environmental problems associated with existing chemical foaming methods. The raw materials of the low-temperature resistant EVA micro-closed-cell foam material in the aforementioned embodiment are fed into a twin-screw extruder according to the specified ratio. The melt temperature is controlled at 170±5℃, and the material undergoes high-precision mechanical extrusion physical foaming, continuously extruding to form EVA micro-foam sheets.

[0032] Among them, the low-temperature resistant POE blend modified EVA resin is obtained by adding 15-20 parts of POE to 100 parts of EVA resin.

[0033] Step 3: After coating the lower surface of the low-temperature buffer foam layer with pre-made graphene-modified polyurethane physical foaming material, the layer is initially cured by constant temperature and static setting to improve the interlayer bonding strength and obtain the sound insulation and antibacterial main foam layer.

[0034] The pre-fabricated graphene-modified polyurethane physical foaming material comprises the following raw materials in parts by weight: 66 parts automotive-grade low-odor, high-activity polyoxypropylene ether triol, 34 parts diphenylmethane diisocyanate, 0.9 parts aqueous graphene dispersion, 1.5 parts organosilicon low-odor foaming agent, 0.4 parts low-VOC reactive composite tertiary amine environmentally friendly catalyst, and 2.5 parts deionized water. The materials are mixed according to the above parts by weight, using high-purity nitrogen as the foaming gas source. The entire foaming process is physical, leaving no chemical residue. The raw materials of the graphene-modified polyurethane physical foaming material are precisely mixed according to the formula, and then subjected to online constant-temperature physical foaming under high pressure and high-purity nitrogen at a foaming pressure of 0.3±0.05MPa to ensure uniform and dense cell structure.

[0035] Step 4: Lay fiberglass mesh on the underside of the not fully cured sound insulation and antibacterial foam layer, and simultaneously heat press it at a constant temperature to obtain a dimensionally stable reinforcing layer.

[0036] When laying the ultra-thin fiberglass mesh, maintain a uniform speed and synchronously press and bond at a constant temperature to ensure no wrinkles or misalignment. The sound insulation and antibacterial main foam layer is fully cured after this step. The step-by-step curing of the sound insulation and antibacterial main foam layer allows the fiberglass mesh to better embed into the surface of the sound insulation and antibacterial main foam layer during this step, forming a protective interlocking structure after hot pressing and increasing the peel strength.

[0037] Step 5: Apply water-based adhesive to the dimensionally stable reinforcing layer, and continuously composite butyl rubber micro-foamed material to obtain a waterproof and non-slip bonding bottom layer. Then, perform constant temperature hot pressing composite of the entire structure under the conditions of hot pressing temperature of 130℃ and pressure of 0.3Mpa. After complete curing by constant temperature air cooling, a five-layer integrated carpet board is obtained. After the composite molded carpet board is completely cured by constant temperature air cooling to eliminate internal stress, it is then subjected to precision trimming, fixed-length cutting, flatness correction, and automotive-specific performance testing. Finally, it is sealed and packaged to obtain a finished automotive foam carpet that meets the vehicle assembly standards.

[0038] Core performance characteristics of finished automotive foam carpets: Carpet resilience is 69%; tested according to ISO 15186-1:2000 reverberation chamber method, the average sound insulation is 26.2dB, and the overall noise reduction in a real vehicle can reach 31dB; VOCs meet the limits according to GB / T 27630; odor level ≤3 according to VDA 270 standard; no deformation at 90℃ high temperature and no cracking at -40℃ low temperature; burning speed ≤30mm / min according to GB 8410 test; compression deformation is 10.6% according to GB / T 6669 test.

[0039] This invention provides a novel method for preparing automotive foam carpets. This method involves fully automated continuous production line production, eliminating the need for specialized custom molds. It simplifies processes, reduces energy consumption, increases production efficiency by more than 35%, and ensures high consistency in product thickness, size, and performance. It also significantly improves the yield rate and greatly reduces production costs, making it suitable for large-scale, standardized mass production of automotive parts.

[0040] The present invention has been disclosed above with reference to preferred embodiments, but it is not intended to limit the present invention. All technical solutions obtained by adopting equivalent substitutions or equivalent transformations fall within the protection scope of the present invention.

Claims

1. A type of automotive foam carpet, characterized in that, It includes a wear-resistant and stain-resistant surface layer, a low-temperature buffer foam layer, a sound-insulating and antibacterial main foam layer, a dimensionally stable reinforcing layer, and a waterproof and non-slip bonding bottom layer arranged from top to bottom, and the layers are composite and molded as one piece; The wear-resistant and stain-resistant surface layer is made of flame-retardant PET needle-punched felt, the low-temperature buffer foam layer is made of EVA micro-closed-cell foam material, the sound-insulating and antibacterial main foam layer is made of graphene-modified polyurethane physical foam material, the dimensionally stable reinforcing layer is made of fiberglass mesh cloth, and the waterproof and anti-slip bonding bottom layer is made of butyl rubber micro-foam material.

2. The automotive foam carpet according to claim 1, characterized in that, The thickness of the wear-resistant and stain-resistant surface layer is 1.5~1.8mm, and the basis weight of the wear-resistant and stain-resistant surface layer is 300~350g / ㎡.

3. The automotive foam carpet according to claim 1, characterized in that, The thickness of the low-temperature buffer foam layer is 2.0~2.5mm, and the density is 140±10kg / m³; And / or, the closed-cell rate of the EVA micro-closed-cell foam material is ≥92%; And / or, the EVA micro-closed-cell foam material comprises the following raw materials in parts by weight: 48-52 parts of POE blended modified EVA resin, 33-36 parts of heavy calcium carbonate, 1.2-1.8 parts of composite weather-resistant heat stabilizer, 1.0-1.3 parts of crosslinking agent, and 0.5-0.8 parts of low-temperature toughening agent; the EVA micro-closed-cell foam material is formed by mixing the raw materials in the above-mentioned parts by weight and using pure mechanical physical foaming.

4. The automotive foam carpet according to claim 1, characterized in that, The thickness of the sound-insulating and antibacterial foam layer is 3.0–3.5 mm, and the density is 100 ± 10 kg / m³. And / or, the graphene-modified polyurethane physical foaming material comprises the following raw materials in parts by weight: 64-67 parts of low-odor, high-activity polyoxypropylene ether triol, 32-35 parts of diphenylmethane diisocyanate, 0.8-1.1 parts of aqueous graphene dispersion, 1.2-1.6 parts of organosilicon low-odor foaming agent, 0.4-0.5 parts of low-VOC reactive composite tertiary amine environmentally friendly catalyst, and 2.2-2.8 parts of deionized water. The graphene-modified polyurethane physical foaming material is formed by mixing the raw materials in the above-mentioned parts by weight and then physically foaming them.

5. The automotive foam carpet according to claim 1, characterized in that, The thickness of the glass fiber mesh is 0.4 to 0.5 mm.

6. The automotive foam carpet according to claim 1, characterized in that, The thickness of the waterproof and anti-slip adhesive base layer is 1.0~1.2mm, and its bottom surface is provided with dotted anti-slip protrusions.

7. A method for preparing automotive foam carpet, characterized in that, include: The surface of the flame-retardant PET needle-punched felt is activated by high-voltage corona treatment, and water-based adhesive is coated on the lower surface of the flame-retardant PET needle-punched felt to obtain a pre-treated wear-resistant and stain-resistant surface layer. The lower surface of the pretreated wear-resistant and stain-resistant surface layer is aligned and hot-pressed with the pre-made EVA micro-closed-cell foam material, and then cooled and shaped at a constant temperature to obtain a low-temperature buffer foam layer. After coating the lower surface of the low-temperature buffer foam layer with a pre-made graphene-modified polyurethane physical foaming material, and then allowing it to stand at a constant temperature, an incompletely cured sound insulation and antibacterial main foam layer is obtained. A fiberglass mesh is laid on the underside of the not fully cured sound insulation and antibacterial foam layer, and then simultaneously hot-pressed at a constant temperature to obtain a fully cured sound insulation and antibacterial foam layer and a dimensionally stable reinforcing layer. Water-based adhesive is applied to the dimensionally stable reinforcing layer, and multi-layer butyl rubber micro-foamed material is composited to obtain a waterproof and non-slip bonding bottom layer. The overall structure is then subjected to constant temperature hot pressing and composite, and after complete curing by constant temperature air cooling, a five-layer integrated foamed carpet is obtained.

8. The method for preparing automotive foam carpet according to claim 7, characterized in that, The coating amount of water-based adhesive on the lower surface of the flame-retardant PET needle-punched felt is 100±5g / ㎡.

9. The method for preparing automotive foam carpet according to claim 7, characterized in that, The hot-pressing temperature for aligning and hot-pressing the lower surface of the pretreated wear-resistant and stain-resistant surface layer with the pre-made EVA micro-closed-cell foam material is 150±5℃, and the hot-pressing pressure is 0.4±0.05MPa.

10. The method for preparing automotive foam carpet according to claim 7, characterized in that, The temperature range of the overall structure isothermal hot-pressed composite is 125-135℃, and the pressure range is 0.25-0.35MPa.

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