EPP material and tatami mats made from this EPP material

Abstract

This application relates to an EPP material and a folding mat using this EPP material, which relates to the field of EPP material technology. The EPP material is formed into a plate by welding EPP particles, and the surface of the plate is coated with a hydrophobic antibacterial paint. The raw materials for preparing the EPP particles include 80-100 parts by weight of polypropylene resin, 1-3 parts by weight of a nucleating agent, 6-8 parts by weight of a modified graphene composite material, 5-10 parts by weight of a flame retardant, 5-15 parts by weight of a reinforcing agent, and 0.5-1.5 parts by weight of a surfactant. The raw materials for preparing the modified graphene composite material include hydrophobic modified graphene oxide, hydrophobic antibacterial nano-zinc oxide, and a modified ammonium polyphosphate coupling agent. The folding mat using this EPP material includes an EPP material, a surface layer, and a sewing thread, and the surface layer and the EPP material are fixedly connected by the sewing thread. This application has the effect of improving the flame retardancy, waterproofness, and antibacterial properties of EPP material, and the resulting tatami mat is environmentally friendly, comfortable, and has a good user experience.

Description

[Technical Field]

[0001] The present application relates to the field of EPP material technology, and in particular to EPP material and folding mats to which this EPP material is applied. [Background technology]

[0002] In modern home life, tatami mats are loved by consumers for their comfort, practicality, and good space utilization, and are widely used in multiple spaces such as bedrooms and living rooms, becoming an important element of home interior decoration. As people's pursuit of improving the quality of life continues to grow, the performance requirements for tatami mat materials are also becoming increasingly strict.

[0003] Expanded polypropylene (EPP) material is a new, high-performance foam material that has attracted attention in recent years in many fields, including packaging and automotive interiors. Its excellent physical properties, such as excellent cushioning, high strength, light weight, and recyclability, have attracted the attention of the home interior industry and are providing a new direction for the innovation of tatami mat materials.

[0004] However, most commonly found tatami mats on the market are made from traditional materials such as sponge or coconut fiber, which pose numerous problems during use. Sponge materials are prone to deformation, have poor breathability, and can lead to bacterial growth over time. Coconut fiber mats, while offering a certain level of breathability, suffer from poor moisture and insect resistance. Furthermore, some products contain excessive adhesives, potentially posing a risk of formaldehyde emissions exceeding standard limits, which can seriously affect user health and experience. Therefore, there is a need to provide EPP materials and tatami mats made from them to improve product performance and user experience. Summary of the Invention [Problem to be solved by the invention]

[0005] This application provides an EPP material and a tatami mat using this EPP material to improve the performance of the tatami mat. [Means for solving the problem]

[0006] The EPP material and the folding mat using this EPP material provided in this application adopt the following technical solutions:

[0007] In the first aspect, the EPP material provided in this application adopts the following technical solutions:

[0008] An EPP material, the EPP material being formed into a plate by welding EPP particles, and a hydrophobic antibacterial paint being applied to the surface of the plate, and the raw material for preparing the EPP particles is 80 to 100 parts by mass of polypropylene resin, 1 to 3 parts by mass of a nucleating agent, 6 to 8 parts by weight of a modified graphene composite material; 5 to 10 parts by mass of a flame retardant, 5 to 15 parts by weight of a reinforcing agent, and containing 0.5 to 1.5 parts by mass of a surfactant, The preparation raw materials for the modified graphene composite include hydrophobic modified graphene oxide, hydrophobic antibacterial nano zinc oxide, and modified ammonium polyphosphate as a coupling agent.

[0009] The hydrophobic graphene oxide in the modified graphene composite slows the transfer of heat and oxygen due to the barrier effect of its sheet layer structure. It also works synergistically with the coupling agent, modified ammonium polyphosphate, to release phosphate ester-based flame retardant active substances during combustion and form a char layer, improving flame retardancy through a dual mechanism of gas and condensed phases. After surface hydrophobization of the hydrophobic modified graphene oxide and hydrophobic antibacterial nano-zinc oxide, a low surface energy interface is established both inside and on the surface of the material, effectively inhibiting moisture penetration. Combined with the optimized dispersion of surfactants in each component, this creates a continuous hydrophobic network, significantly improving waterproofing. Hydrophobic antibacterial nano-zinc oxide combines physical shielding and chemical antibacterial properties. The antibacterial components carried in it can disrupt bacterial cell membranes through contact or sustained release, inhibiting the attachment and proliferation of microorganisms. When combined with a hydrophobic antibacterial coating applied to the surface, this creates a dual antibacterial system of internal reinforcement and surface protection, achieving long-term antibacterial activity against bacteria such as E. coli and Staphylococcus aureus. The above components exert a synergistic effect with polypropylene resin, nucleating agent, flame retardant, toughening agent, and surfactant to adjust the performance of EPP materials and improve their flame retardancy, waterproofing, and antibacterial properties, meeting the application needs of multifunctional lightweight materials.

[0010] Preferably, the raw materials for preparing the hydrophobically modified graphene oxide include graphene oxide, hydrazine hydrate, and octadecylamine.

[0011] Hydrazine hydrate, as a reducing agent, removes hydrophilic groups, such as epoxy and hydroxyl groups, from the surface of graphene oxide, partially restoring the conjugated structure and improving thermal conductivity and mechanical properties. Octadecylamine is grafted onto the surface of the graphene oxide sheets via an amidation reaction. Its long-chain alkyl groups form a hydrophobic barrier, transforming graphene oxide from hydrophilic to hydrophobic, improving its dispersibility and compatibility in the nonpolar polypropylene matrix. In EPP materials, the modified graphene oxide slows the rate of heat and oxygen transfer during combustion due to the physical barrier effect of the sheet layer structure. It also forms a composite flame-retardant system with the modified ammonium polyphosphate coupling agent, improving condensed-phase flame retardancy. The hydrophobic surface interacts synergistically with the hydrophobic antibacterial nano-zinc oxide in the interior and the hydrophobic antibacterial coating on the surface to create a continuous, low-surface-energy network from the interior to the surface, effectively inhibiting moisture penetration. The uniformly dispersed graphene oxide strengthens the intermolecular force of the polymer through π-π conjugation, indirectly improving the overall strength and weather resistance of the material, thereby improving the flame retardancy and waterproofness of the EPP material.

[0012] Preferably, the mass ratio of the graphene oxide, hydrazine hydrate, and octadecylamine is 1:0.02:(0.25 to 0.35).

[0013] The hydrophobically modified graphene oxide prepared at the above mass ratio has excellent flame retardancy and hydrophobicity.

[0014] Preferably, the preparation raw materials for the hydrophobic antibacterial nano zinc oxide include nano zinc oxide, silver nitrate, and isopropyl titanium triisostearate.

[0015] After reduction with silver nitrate, nanosilver particles are formed and supported on the surface of nanozinc oxide. The sustained release of silver ions disrupts the permeability of bacterial cell membranes, synergizing with the metal ion antibacterial activity of zinc oxide itself to enhance antibacterial properties. Hydrophobically modifying isopropyl titanium triisostearate, its amphiphilic structure of long-chain alkyl groups and polar groups, forms a hydrophobic coating on the surface of nanozinc oxide, improving dispersion within the non-polar polypropylene matrix and reducing nanoparticle aggregation. In EPP materials, the hydrophobic antibacterial nanozinc oxide exerts long-lasting antibacterial activity through the silver-zinc composite antibacterial system, inhibiting the adhesion and proliferation of microorganisms both inside and on the surface of the material. The hydrophobic surface forms a low-surface-energy network with the hydrophobically modified graphene oxide in the material and the hydrophobic antibacterial coating applied to the surface, inhibiting moisture penetration, eliminating the humid environment where bacteria thrive, and improving the water resistance of the material. Furthermore, the uniformly dispersed nano zinc oxide particles act as a physical barrier to retard heat transfer, and in combination with the coupling agent, modified ammonium polyphosphate, enhance the flame retardancy of the material, thereby improving the antibacterial and waterproof properties of the EPP material.

[0016] Preferably, the mass ratio of the nano zinc oxide, silver nitrate, and isopropyl titanium triisostearate is 1:0.15:(0.03 to 0.05).

[0017] The hydrophobic antibacterial nano zinc oxide prepared in the above weight ratio has excellent waterproof and antibacterial properties.

[0018] Preferably, the toughening agent comprises an ethylene-octene copolymer and an ethylene propylene diene rubber (EPDM).

[0019] Ethylene-octene copolymer (EOC) is a polyolefin elastomer with excellent compatibility with the polypropylene matrix. Its flexible chain segments form an island-sea structure within the matrix. When the material is subjected to external impact, the elastomer phase deforms, absorbing energy and inducing the formation of rhinestones and shear bands within the matrix, slowing crack propagation. Ethylene-propylene-diene rubber (EPDM) acts as the rubber phase, imparting excellent weather resistance through its unsaturated double bond structure. The rubber particles dispersed throughout the polypropylene matrix act as stress concentration points, promoting the dispersion of impact energy at the multiphase interface and effectively improving elongation at break. When these two components are combined, EOC strengthens interfacial bonding with polypropylene through intermolecular forces, while EPDM optimizes the phase distribution through physical crosslinking, forming a reinforcing elastomer-rubber network. This significantly improves rebound performance while maintaining the lightweight properties of EPP. In addition, the toughening agent can adjust the viscosity of the polypropylene melt, promote uniform nucleation and stable growth of bubbles during the foaming process, and avoid bubble collapse and coalescence, thereby synergistically improving the overall mechanical properties and processing stability of the EPP material.

[0020] Preferably, the raw materials for preparing the hydrophobic antibacterial paint include 40 to 50 parts by mass of a silicone-modified polyurethane resin, 2 to 3 parts by mass of a quaternary ammonium salt-based antibacterial agent, 4 to 6 parts by mass of hydrophobic nano-titanium dioxide, 3 to 5 parts by mass of a film-forming aid, 0.03 to 0.05 parts by mass of a dispersant, 0.5 to 1 part by mass of a leveling agent, and 0.3 to 0.5 parts by mass of an antifoaming agent.

[0021] Silicone-modified polyurethane resin serves as the film-forming body. The siloxane groups in its molecular chain are aligned in a specific direction on the coating surface, forming a low-surface-energy interface that effectively blocks moisture penetration and imparts excellent flexibility and adhesion to the coating. The quaternary ammonium salt antibacterial agent enhances antibacterial properties by disrupting the integrity of bacterial cell membranes through electrostatic interactions between cationic active groups and bacterial cell membranes, inhibiting microbial growth. Hydrophobic nano-titanium dioxide is uniformly dispersed in the coating. Its nano-sized particles enhance hydrophobicity through the synergistic effect of its rough surface and low surface energy, and also act as a physical barrier to inhibit bacterial adhesion, forming a dual chemical-physical antibacterial mechanism with the quaternary ammonium salt antibacterial agent. The film-forming aid lowers the minimum resin deposition temperature, ensuring complete coating formation at room temperature. The combined use of dispersants, leveling agents, and antifoaming agents ensures uniform nanoparticle dispersion and a smooth coating surface, avoiding defects such as agglomeration and shrinkage cavities. Each component works in harmony with the other, exerting a synergistic effect to form an integrated coating layer on the surface of the EPP board that combines hydrophobic protection and long-lasting antibacterial properties, thereby effectively improving the waterproof and antibacterial properties of the material.

[0022] Preferably, the method for preparing the EPP material comprises: The process includes the steps of mixing polypropylene resin, a nucleating agent, a modified graphene composite, a flame retardant, a reinforcing agent, and a surfactant, stirring, melting, kneading, and extruding to granulate, thereby obtaining pretreated particles; adding carbon dioxide to the pretreated particles, sealing, heating and pressurizing the mixture to allow the carbon dioxide to fully penetrate the particles, and then reducing the pressure to normal pressure to foam the particles, thereby producing EPP particles; evenly placing the EPP particles in a mold and hot-press welding them to obtain EPP plate material; and applying a hydrophobic antibacterial paint to the surface of the EPP plate material, drying it by heating, and curing it to obtain an EPP material.

[0023] The EPP material prepared according to the above steps has excellent flame retardancy, waterproof and antibacterial properties, meeting the application needs of multifunctional lightweight materials.

[0024] In a second aspect, the present application further provides a folding mat applied with EPP material, and adopts the following technical solutions: A folding mat made of EPP material, comprising an EPP material, a surface layer, and a sewing thread, wherein the EPP material is in the shape of a rectangular plate, the surface layer covers one surface and four side walls of the EPP material, and the surface layer and the EPP material are fixedly connected with the sewing thread.

[0025] EPP's lightweight and strong properties allow folding mats to be easily portable and resilient, meeting the needs of frequent movement and withstanding foot traffic during daily use. The surface layer, made of flexible fabric, covers the EPP, improving comfort and aesthetics. It also forms a physical barrier to protect the EPP from direct erosion by dust and dirt, and, combined with the EPP's inherent hydrophobic and antibacterial properties, effectively reduces mold growth and bacterial adhesion. The stitching securely connects the surface layer to the EPP, preventing misalignment over time and dispersing localized stress through rational stitch spacing and design, enhancing the overall durability of the structure. This results in a multi-functional folding mat that combines lightweight comfort, safety, and durability.

[0026] Preferably, the material of the surface layer includes one of grass knitting, PP knitting, modified paper knitting, cloth knitting, and rattan knitting.

[0027] The surface layer material can provide the tatami mat material with excellent appearance and comfort.

[0028] To summarize the above, the present application includes at least one of the following beneficial technical effects: 1. The hydrophobic graphene oxide in the modified graphene composite retards heat and oxygen transmission through its barrier properties due to its sheet layer structure. It also works synergistically with the coupling agent, modified ammonium polyphosphate, to release phosphate ester-based flame retardant active substances during combustion and form a char layer, improving flame retardancy through a dual mechanism of gas and condensed phases. After surface hydrophobization of the hydrophobic modified graphene oxide and hydrophobic antibacterial nano-zinc oxide, a low surface energy interface is established both inside and on the surface of the material, effectively inhibiting moisture penetration. Combined with the optimized dispersion of surfactants in each component, this creates a continuous hydrophobic network, significantly improving waterproofing. Hydrophobic antibacterial nano-zinc oxide combines physical shielding and chemical antibacterial properties. The antibacterial components carried in it can disrupt bacterial cell membranes through contact or sustained release, inhibiting the attachment and proliferation of microorganisms. When combined with a hydrophobic antibacterial coating applied to the surface, this creates a dual antibacterial system of internal reinforcement and surface protection, achieving long-term antibacterial activity against bacteria such as E. coli and Staphylococcus aureus. The above components exert a synergistic effect with polypropylene resin, nucleating agent, flame retardant, toughening agent, and surfactant to adjust the performance of EPP materials and improve their flame retardancy, waterproofing, and antibacterial properties, meeting the application needs of multifunctional lightweight materials.

[0029] 2. Hydrazine hydrate, as a reducing agent, removes hydrophilic groups, such as epoxy and hydroxyl groups, from the surface of graphene oxide, partially restoring the conjugated structure and improving thermal conductivity and mechanical properties. Octadecylamine is grafted onto the surface of the graphene oxide sheet layers through an amidation reaction. Its long-chain alkyl groups form a hydrophobic barrier, transforming graphene oxide from hydrophilic to hydrophobic, improving its dispersibility and compatibility in the non-polar polypropylene matrix. In EPP materials, the modified graphene oxide slows the rate of heat and oxygen transfer during combustion due to the physical barrier effect of the sheet layer structure. It also forms a composite sheet-carbon flame-retardant system with the coupling agent, modified ammonium polyphosphate, improving condensed-phase flame retardancy. The hydrophobic surface interacts synergistically with the hydrophobic antibacterial nano-zinc oxide in the interior and the hydrophobic antibacterial coating on the surface to create a continuous, low-surface-energy network from the interior to the surface, effectively inhibiting moisture penetration. The uniformly dispersed graphene oxide strengthens the intermolecular force of the polymer through π-π conjugation, indirectly improving the overall strength and weather resistance of the material, thereby improving the flame retardancy and waterproofness of the EPP material.

[0030] 3. After silver nitrate reduction, nano-silver particles are formed and supported on the surface of nano-zinc oxide. This releases silver ions, disrupting the permeability of bacterial cell membranes. This synergistic effect with the metal ion antibacterial activity of zinc oxide itself enhances antibacterial properties. Hydrophobically modifying isopropyl titanium triisostearate, its amphiphilic structure consisting of long-chain alkyl groups and polar groups, forms a hydrophobic coating on the surface of nano-zinc oxide, improving dispersion within the non-polar polypropylene matrix and reducing nanoparticle aggregation. In EPP materials, the hydrophobic antibacterial nano-zinc oxide exhibits long-lasting antibacterial activity through its silver-zinc composite antibacterial system, inhibiting the adhesion and proliferation of microorganisms both inside and on the surface of the material. The hydrophobic surface forms a low-surface-energy network with the hydrophobically modified graphene oxide in the material and the hydrophobic antibacterial coating applied to the surface, inhibiting moisture penetration, eliminating the humid environment where bacteria thrive, and improving the material's water resistance. Furthermore, the uniformly dispersed nano zinc oxide particles act as a physical barrier to retard heat transfer, and in combination with the coupling agent, modified ammonium polyphosphate, enhance the flame retardancy of the material, thereby improving the antibacterial and waterproof properties of the EPP material. [Brief explanation of the drawings]

[0031] [Figure 1] 1 is a schematic diagram of the cross-sectional structure of a folding mat to which an EPP material is applied in Application Example 1 of the present application. [Figure 2] 1 is a schematic diagram of the cross-sectional structure of a folding mat to which an EPP material is applied in Application Example 2 of the present application. [Figure 3] FIG. 1 is a schematic diagram of the cross-sectional structure of a folding mat to which an EPP material is applied in Application Example 3 of the present application. [Figure 4] FIG. 10 is a schematic diagram of the cross-sectional structure of a folding mat to which an EPP material is applied in Application Example 5 of the present application. DETAILED DESCRIPTION OF THE INVENTION

[0032] The present application discloses an EPP material and a tatami mat using this EPP material. Unless otherwise specified, the raw materials used in the present application are commercially available raw materials. The present application will be described in more detail below with reference to examples, comparative examples, and application examples.

[0033] Raw material description: Graphene oxide was purchased from Beijing Deke Island Technology Co., Ltd., and hydrazine hydrate (CAS number: 7803-57-8), octadecylamine (CAS number: 124-30-1), nano zinc oxide (CAS number: 1314-13-2), particle size 50 nm, silver nitrate (CAS number: 7761-88-8), sodium borohydride (CAS number: 16940-66-2), isopropyl titanium triisostearate (CAS number: 61417-49-0), ammonium polyphosphate (CA S number: 68333-79-9), molecular weight 10000, γ-aminopropyltriethoxysilane (CAS number: 57022-99-0), polyvinyl alcohol (CAS number: 9002-89-5), hydrophobic nano titanium dioxide (CAS number: 13463-67-7), particle size 30 nm, dispersant was sodium polyacrylate (CAS number 9003-04-7), silicone modified polyurethane resin purchased from Fenyangtang Co., Ltd., and film-forming aid was 2,2,4-trimethyl-1,3-pentanediol. The quaternary ammonium salt antibacterial agent is dodecyldimethylbenzylammonium chloride (CAS number: 139-07-1), the leveling agent is dimethicone (CAS number: 9006-65-9), the antifoaming agent is Dow Corning DC-57, polypropylene resin (CAS number: 9003-07-0), the melt flow rate is 30 g / 10 min, and the nucleating agent is talc. The EPP material has a foaming ratio of 10 to 35 times and a thickness of 2 to 6 cm. The surface layer is made of PP knitted fabric, and the sewing thread is high-strength sewing thread.

[0034] Example 1 Preparation of modified graphene composites 7.87 g of graphene oxide was dispersed in 100 mL of deionized water, 0.16 g of hydrazine hydrate was added, and the mixture was stirred at 60°C and 200 rpm for 1 hour. After centrifugation and washing with deionized water, the mixture was dispersed in 150 mL of ethanol, 1.97 g of octadecylamine was added, and the mixture was refluxed at 70°C for 2 hours. After filtration, the mixture was dried at 60°C to obtain hydrophobically modified graphene oxide.

[0035] 8.47 g of nano-zinc oxide was dispersed in 60 mL of deionized water, 1.27 g of silver nitrate was added, and the mixture was ultrasonicated for 30 minutes. 10 mL of 1 mol / L aqueous sodium borohydride solution was added dropwise, and the mixture was stirred at 200 rpm for 30 minutes. The mixture was then centrifuged and washed with deionized water to obtain modified nano-zinc oxide. 0.26 g of the modified nano-zinc oxide and isopropyl titanium triisostearate were dispersed in 100 mL of ethanol, and the mixture was stirred at 70°C for 2 hours at 200 rpm. After centrifugation, the mixture was vacuum dried at 40°C to obtain hydrophobic antibacterial nano-zinc oxide.

[0036] The ammonium polyphosphate was dried under vacuum at 60°C for 4 hours to obtain anhydrous ammonium polyphosphate. 2 g of γ-aminopropyltriethoxysilane was dissolved in 100 mL of absolute ethanol, and glacial acetic acid was added dropwise to adjust the pH to 4.5. The mixture was stirred in a 60°C water bath for 30 minutes to obtain a silanol solution. 11.53 g of anhydrous ammonium polyphosphate was added to the silanol solution and the mixture was stirred at 60°C at 200 rpm for 1 hour. After the reaction was completed, the mixture was centrifuged, washed with absolute ethanol, and dried under vacuum at 80°C to obtain the modified ammonium polyphosphate, which is a coupling agent.

[0037] 2.31 g of hydrophobic modified graphene oxide, 5.76 g of hydrophobic antibacterial nano-zinc oxide, 11.53 g of modified ammonium polyphosphate as a coupling agent, and 0.4 g of polyvinyl alcohol were dispersed in 100 mL of deionized water, stirred at 200 rpm for 30 min, and ultrasonically treated for 60 min to obtain a mixture. The mixture was then spray-dried, with the inlet temperature at 190°C, the outlet temperature at 90°C, the atomizing disk rotation speed at 10,000 rpm, the feed rate at 5 mL / min, and the atomized droplet particle size at 50 μm, to obtain a modified graphene composite filler.

[0038] Preparation of hydrophobic antibacterial paint 4 g of hydrophobic nano-titanium dioxide and 0.03 g of dispersant were dispersed in 20 g of deionized water, ultrasonicated for 30 minutes, and stirred at 1500 rpm for 10 minutes. 40 g of silicone-modified polyurethane resin and 3 g of film-forming agent were added, and the mixture was stirred at 800 rpm for 30 minutes. 2 g of quaternary ammonium salt antibacterial agent was added, and the mixture was stirred at 500 rpm for 15 minutes. 0.5 g of leveling agent and 0.3 g of antifoaming agent were added, and the mixture was stirred at 300 rpm for 10 minutes. The viscosity was adjusted to 4000 mPa·s with deionized water, and the mixture was filtered through a 100-mesh filter to remove foreign matter, resulting in a hydrophobic antibacterial paint.

[0039] Preparation of EPP material 80g of polypropylene resin, 1g of nucleating agent, 6g of modified graphene composite, 5g of flame retardant, 5g of toughening agent, and 0.5g of surfactant were mixed and stirred at 200 rpm for 15 minutes. The mixture was melted, kneaded, extruded, and granulated in a twin-screw extruder at 200-220°C and a screw rotation speed of 200 rpm to obtain pretreated particles. The pretreated particles were then placed in a high-pressure foaming oven, added with carbon dioxide, sealed, heated to 140°C, and maintained at 2.5 MPa for 15 minutes to allow the carbon dioxide to penetrate the particles. The oven was then quickly depressurized to atmospheric pressure to foam the particles, producing EPP particles. The EPP particles were then evenly placed in a mold and fused to a plate using a hot press welding machine at 165°C, 0.8 MPa, and for 6 minutes to obtain EPP plate. A hydrophobic antibacterial coating was applied to the surface of the EPP plate and dried and cured at 80°C for 2 hours to obtain EPP material.

[0040] Example 2 Preparation of modified graphene composites 7.3 g of graphene oxide was dispersed in 100 mL of deionized water, 0.15 g of hydrazine hydrate was added, and the mixture was stirred at 60°C and 200 rpm for 1 hour. After centrifugation and washing with deionized water, the mixture was dispersed in 150 mL of ethanol, 2.55 g of octadecylamine was added, and the mixture was refluxed at 70°C for 2 hours. After filtration, the mixture was dried at 60°C to obtain hydrophobically modified graphene oxide.

[0041] 8.33 g of nano-zinc oxide was dispersed in 60 mL of deionized water, 1.25 g of silver nitrate was added, and the mixture was ultrasonicated for 30 minutes. 10 mL of 1 mol / L aqueous sodium borohydride solution was added dropwise, and the mixture was stirred at 200 rpm for 30 minutes. The mixture was then centrifuged and washed with deionized water to obtain modified nano-zinc oxide. 0.42 g of the modified nano-zinc oxide and isopropyl titanium triisostearate were dispersed in 100 mL of ethanol, and the mixture was stirred at 70°C for 2 hours at 200 rpm. After centrifugation, the mixture was vacuum-dried at 40°C to obtain hydrophobic antibacterial nano-zinc oxide.

[0042] The ammonium polyphosphate was dried under vacuum at 60°C for 4 hours to obtain anhydrous ammonium polyphosphate. 2 g of γ-aminopropyltriethoxysilane was dissolved in 100 mL of absolute ethanol, and glacial acetic acid was added dropwise to adjust the pH to 4.5. The mixture was stirred in a 60°C water bath for 30 minutes to obtain a silanol solution. 11.53 g of anhydrous ammonium polyphosphate was added to the silanol solution and the mixture was stirred at 60°C at 200 rpm for 1 hour. After the reaction was completed, the mixture was centrifuged, washed with absolute ethanol, and dried under vacuum at 80°C to obtain the modified ammonium polyphosphate, which is a coupling agent.

[0043] 2.31 g of hydrophobic modified graphene oxide, 5.76 g of hydrophobic antibacterial nano-zinc oxide, 11.53 g of modified ammonium polyphosphate as a coupling agent, and 0.4 g of polyvinyl alcohol were dispersed in 100 mL of deionized water, stirred at 200 rpm for 30 min, and ultrasonically treated for 60 min to obtain a mixture. The mixture was spray-dried at an inlet temperature of 190°C, an outlet temperature of 90°C, a rotation speed of the atomizing disk of 10,000 rpm, a feed rate of 5 mL / min, and a particle size of 50 μm to obtain a modified graphene composite filler.

[0044] Preparation of hydrophobic antibacterial paint 6 g of hydrophobic nano-titanium dioxide and 0.05 g of dispersant were dispersed in 20 g of deionized water, ultrasonicated for 30 minutes, and stirred at 1500 rpm for 10 minutes. 50 g of silicone-modified polyurethane resin and 5 g of film-forming agent were added, and the mixture was stirred at 800 rpm for 30 minutes. 3 g of quaternary ammonium salt antibacterial agent was added, and the mixture was stirred at 500 rpm for 15 minutes. 1 g of leveling agent and 0.5 g of antifoaming agent were added, and the mixture was stirred at 300 rpm for 10 minutes. The viscosity was adjusted to 4000 mPa·s using deionized water, and the mixture was filtered through a 100-mesh filter to remove foreign matter, resulting in a hydrophobic antibacterial paint.

[0045] Preparation of EPP material 100g of polypropylene resin, 3g of nucleating agent, 8g of modified graphene composite, 10g of flame retardant, 15g of reinforcing agent, and 1.5g of surfactant were mixed and stirred at 200 rpm for 15 minutes. The mixture was then melted and kneaded in a twin-screw extruder at a temperature of 200-220℃ and a screw rotation speed of 200 rpm, extruded, and granulated to obtain pretreated particles. The pretreated particles were then placed in a high-pressure foaming oven, carbon dioxide was added, and the oven was sealed and heated to 140℃. The temperature was raised to 165°C and maintained at a pressure of 2.5MPa for 15 minutes to allow the carbon dioxide to fully penetrate the particles, and then the pressure was quickly reduced to normal pressure to allow foaming, producing EPP particles. The EPP particles were evenly placed in a mold and fused to a plate using a hot press welding device at a temperature of 165°C, a pressure of 0.8MPa, and a time of 6 minutes to obtain an EPP plate. A hydrophobic antibacterial paint was applied to the surface of the EPP plate, and it was dried and cured at 80°C for 2 hours to obtain an EPP material.

[0046] Example 3 Preparation of modified graphene composites 7.58 g of graphene oxide was dispersed in 100 mL of deionized water, 0.15 g of hydrazine hydrate was added, and the mixture was stirred at 60°C and 200 rpm for 1 hour. After centrifugation and washing with deionized water, the mixture was dispersed in 150 mL of ethanol, 2.27 g of octadecylamine was added, and the mixture was refluxed at 70°C for 2 hours. After filtration, the mixture was dried at 60°C to obtain hydrophobically modified graphene oxide.

[0047] 8.4 g of nano-zinc oxide was dispersed in 60 mL of deionized water, 1.26 g of silver nitrate was added, and the mixture was ultrasonicated for 30 minutes. 10 mL of 1 mol / L aqueous sodium borohydride solution was added dropwise, and the mixture was stirred at 200 rpm for 30 minutes. The mixture was then centrifuged and washed with deionized water to obtain modified nano-zinc oxide. 0.34 g of the modified nano-zinc oxide and isopropyl titanium triisostearate were dispersed in 100 mL of ethanol, and the mixture was stirred at 70°C for 2 hours at 200 rpm. After centrifugation, the mixture was vacuum dried at 40°C to obtain hydrophobic antibacterial nano-zinc oxide.

[0048] The ammonium polyphosphate was dried under vacuum at 60°C for 4 hours to obtain anhydrous ammonium polyphosphate. 2 g of γ-aminopropyltriethoxysilane was dissolved in 100 mL of absolute ethanol, and glacial acetic acid was added dropwise to adjust the pH to 4.5. The mixture was stirred in a 60°C water bath for 30 minutes to obtain a silanol solution. 11.53 g of anhydrous ammonium polyphosphate was added to the silanol solution and the mixture was stirred at 60°C at 200 rpm for 1 hour. After the reaction was completed, the mixture was centrifuged, washed with absolute ethanol, and dried under vacuum at 80°C to obtain the modified ammonium polyphosphate, which is a coupling agent.

[0049] 2.31 g of hydrophobic modified graphene oxide, 5.76 g of hydrophobic antibacterial nano-zinc oxide, 11.53 g of modified ammonium polyphosphate as a coupling agent, and 0.4 g of polyvinyl alcohol were dispersed in 100 mL of deionized water, stirred at 200 rpm for 30 min, and ultrasonically treated for 60 min to obtain a mixture. The mixture was spray-dried at an inlet temperature of 190°C, an outlet temperature of 90°C, a rotation speed of the atomizing disk of 10,000 rpm, a feed rate of 5 mL / min, and a particle size of 50 μm to obtain a modified graphene composite filler.

[0050] Preparation of hydrophobic antibacterial paint 5g of hydrophobic nano-titanium dioxide and 0.04g of dispersant were dispersed in 20g of deionized water, ultrasonicated for 30min, and stirred at 1500rpm for 10min. 45g of silicone-modified polyurethane resin and 4g of film-forming agent were added, and stirred at 800rpm for 30min. 2.5g of quaternary ammonium salt antibacterial agent was added, and stirred at 500rpm for 15min. 0.75g of leveling agent and 0.4g of antifoaming agent were added, and stirred at 300rpm for 10min. The viscosity was adjusted to 4000mPa·s with deionized water, and the mixture was filtered through a 100-mesh filter to remove foreign matter, resulting in a hydrophobic antibacterial paint.

[0051] Preparation of EPP material 90g of polypropylene resin, 2g of nucleating agent, 7g of modified graphene composite, 7.5g of flame retardant, 10g of toughening agent, and 1g of surfactant were mixed and stirred at 200 rpm for 15 minutes. The mixture was melted, kneaded, extruded, and granulated in a twin-screw extruder at 200-220°C and a screw rotation speed of 200 rpm to obtain pretreated particles. The pretreated particles were then placed in a high-pressure foaming oven, carbon dioxide was added, and the oven was sealed. The temperature was raised to 140°C and a pressure of 2.5 MPa was maintained for 15 minutes to allow the carbon dioxide to fully penetrate the particles. The oven was then quickly depressurized to atmospheric pressure to foam the particles, producing EPP particles. The EPP particles were then evenly placed in a mold and fused to a plate using a hot press welding machine at 165°C, a pressure of 0.8 MPa, and a time of 6 minutes to obtain EPP plate. A hydrophobic antibacterial coating was applied to the surface of the EPP plate and dried and cured at 80°C for 2 hours to obtain EPP material.

[0052] Example 4 Example 4 is basically the same as Example 3, and the only difference between Example 4 and Example 3 is that in Example 4, the amount of graphene oxide used is 8.55 g, the amount of hydrazine hydrate used is 0.17 g, and the amount of octadecylamine used is 1.28 g.

[0053] Example 5 Example 5 is basically the same as Example 3, and the only difference between Example 5 and Example 3 is that in Example 5, the amount of graphene oxide used is 6.8 g, the amount of hydrazine hydrate used is 0.14 g, and the amount of octadecylamine used is 3.06 g.

[0054] Example 6 Example 6 is basically the same as Example 3, and the only difference between Example 6 and Example 3 is that in Example 6, hydrazine hydrate is not added when preparing the modified graphene composite material.

[0055] Example 7 Example 7 is basically the same as Example 3, and the only difference between Example 7 and Example 3 is that in Example 7, the amount of nano zinc oxide used is 8.62 g, the amount of silver nitrate used is 1.29 g, and the amount of isopropyl titanium triisostearate is 0.09 g.

[0056] Example 8 Example 8 is basically the same as Example 3, and the only difference between Example 8 and Example 3 is that in Example 8, the amount of nano zinc oxide used is 8 g, the amount of silver nitrate used is 1.2 g, and the amount of isopropyl titanium triisostearate is 0.8 g.

[0057] Example 9 Example 9 is basically the same as Example 3, and the only difference between Example 9 and Example 3 is that in Example 9, no silver nitrate is added when preparing the hydrophobic antibacterial nano-silver oxide.

[0058] (Comparative Example 1) Comparative Example 1 was basically the same as Example 3, and the only difference between Comparative Example 1 and Example 3 was that in Comparative Example 1, hydrophobically modified graphene oxide was replaced with graphene oxide.

[0059] (Comparative Example 2) Comparative Example 2 is basically the same as Example 3, and the only difference between Comparative Example 2 and Example 3 is that in Comparative Example 2, the hydrophobic antibacterial nano zinc oxide is replaced with nano zinc oxide.

[0060] The EPP material prepared in Example 3 was selected to make a tatami mat.

[0061] (Application example 1) Referring to FIG. 1, the folded mat is made of EPP material 1, and includes EPP material 1, a surface layer 2, and sewing thread 3, where EPP material 1 is a rectangular plate-shaped integral structure, surface layer 2 covers one surface and four side walls of EPP material 1, and surface layer 2 and EPP material 1 are fixed and connected by sewing thread 3, and sewing thread 3 is uniformly distributed around the wrapped side walls of EPP material 1.

[0062] (Application example 2) Referring to Figure 2, the difference between Application Example 2 and Application Example 1 is that Application Example 2 further includes a side enclosing layer 4 located outside the surface layer 2 and covering the four side walls of the EPP material 1, the side enclosing layer 4 is made of a wear-resistant fabric, and the surface layer 2, the side enclosing layer 4, and the EPP material 1 are fixedly connected by sewing threads 3, which are uniformly distributed around the wrapped side walls of the EPP material 1.

[0063] (Application example 3) Referring to Figure 3, the difference between Application Example 3 and Application Example 2 is that Application Example 3 further includes a cushioning layer 5 located on the side not covered by the surface layer of the EPP material 1 and in close contact with the surface of the EPP material; after the cushioning layer 5 and the EPP material 1 are combined, their edges are covered by the surface layer 2 and the side surrounding layer 4; the surface layer 2, the side surrounding layer 4, the cushioning layer 5, and the EPP material 1 are fixedly connected by sewing thread 3, which is uniformly distributed around the wrapped side wall of the EPP material 1.

[0064] (Application example 4) Application Example 4 is based on Application Example 3, and the only difference between Application Example 4 and Application Example 3 is that the cushion layer 5 in Application Example 4 is made of an anti-slip material, which increases the coefficient of friction with the contact surface, effectively preventing the tatami mat from slipping due to human movement and reducing the risk of accidentally slipping and rolling or losing balance in sitting posture.

[0065] (Application example 5) Referring to FIG. 4, the difference between Application Example 5 and Application Example 3 is that in Application Example 5, the EPP material 1 is a rectangular plate-shaped laminated support structure, and uses EPP plate materials with two expansion rates, which are successively a first EPP plate material 11 with an expansion rate of 25 times, a second EPP plate material 12 with an expansion rate of 10 times, and a first EPP plate material 11 with an expansion rate of 25 times.

[0066] Performance Detection Test EPP material performance test (1) Based on "GB / T 2406.2-2009 Plastics - Determination of Combustion Behavior by Oxygen Index Method - Part 2: Room Temperature Test", the oxygen index of the samples produced in the examples and comparative examples was tested. Five samples were tested for each sample, and the average value was taken after the measurement. The results are recorded in Table 1.

[0067] (2) Based on "GB / T 1034-2008 Plastics - Measurement of Water Absorption," the samples prepared in the examples and comparative examples were immersed in distilled water for 24 hours, and the water absorption of the samples was tested and calculated as follows: Water absorption (%) = (mass after immersion - mass before immersion) / mass before immersion x 100%. The results are recorded in Table 1.

[0068] (3) Based on "GB / T 31402-2015 Plastics: Test Method for Antibacterial Performance of Plastic Surfaces," the antibacterial rates of the samples prepared in the Examples and Comparative Examples against Escherichia coli, Staphylococcus aureus, and Candida albicans were tested, and the results were recorded in Table 1.

[0069] Flame retardant, waterproof and antibacterial properties of EPP material [Table 1]

[0070] From Table 1, it can be seen that the oxygen index of Examples 1 to 3 is greater than 31.7%, the water absorption rate is less than 0.5%, the antibacterial rate against Escherichia coli is greater than 99.5%, the antibacterial rate against Staphylococcus aureus is greater than 99.2%, and the antibacterial rate against Candida albicans is greater than 98.8%, which indicates that the EPP material produced in this application has excellent flame retardancy, waterproofness, and antibacterial properties.

[0071] As can be seen from Table 1, the only differences between Examples 4, 5, and 6 and Example 3 are that in Example 4, the mass ratio of graphene oxide, hydrazine hydrate, and octadecylamine was 1:0.02:0.15, in Example 5, the mass ratio of graphene oxide, hydrazine hydrate, and octadecylamine was 1:0.02:0.45, and in Example 6, hydrazine hydrate was not added when preparing the modified graphene composite material. Examples 4, 5, and 6 had lower performance than Example 3, because the blending ratio range was violated and the deviation in the amount used reduced dispersibility, flame retardancy, and hydrophobicity. Furthermore, because hydrazine hydrate was not added, graphene oxide was not reduced, the conjugated structure was reduced, and flame retardancy was significantly reduced, and the synergistic effect between the components was also affected.

[0072] As can be seen from Table 1, the only differences between Examples 7, 8, and 9 and Example 3 are that in Example 7, the mass ratio of nano zinc oxide, silver nitrate, and isopropyl titanium triisostearate was 1:0.15:0.01, and in Example 8, the mass ratio of nano zinc oxide, silver nitrate, and isopropyl titanium triisostearate was 1:0.15:0.1. In Example 9, no silver nitrate was added when preparing the hydrophobic antibacterial nano silver oxide. Examples 7, 8, and 9 had lower performance than Example 3. This is because the optimal ratio was not met, which affected the synergistic interaction between the components and also affected the waterproofing and antibacterial properties. Furthermore, the absence of nano silver oxide affected the antibacterial synergistic interaction between the components, resulting in a significant decrease in antibacterial properties.

[0073] As can be seen from Table 1, the only difference between Comparative Example 1 and Example 3 is that hydrophobically modified graphene oxide was replaced with graphene oxide in Comparative Example 1. The performance of Comparative Example 1 was clearly inferior to that of Example 3. This is because the lack of reduction treatment and hydrophobic modification treatment reduced the dispersibility and compatibility of graphene oxide, weakening the synergistic effect and resulting in reduced performance.

[0074] As can be seen from Table 1, the only difference between Comparative Example 2 and Example 3 is that in Comparative Example 2, the hydrophobic antibacterial nano-zinc oxide is replaced with nano-zinc oxide. The performance of Comparative Example 2 is significantly lower than that of Example 3. This is because the hydrophobic antibacterial nano-zinc oxide is replaced with nano-zinc oxide, which results in the lack of hydrophobic treatment and silver loading, which significantly reduces the antibacterial and hydrophobic properties, and also affects the synergistic effects between the components, resulting in a significant decrease in performance.

[0075] Tatami mat performance test The tatami mat manufactured in Example 5 was subjected to a flame retardancy test (GB / T 2406.2-2009 Plastics, Determination of Combustion Behavior by the Oxygen Index Method, Part 2: Room Temperature Test), a combustion product test (combustion product test), a formaldehyde content test, a thermal conductivity test (GB / T 10294-2008 Determination of Steady-State Thermal Resistance and Related Properties of Thermal Insulation Materials, Protective Hot Plate Method), an antibacterial test (E. coli), a rebound rate test (GB / T 6670-2008 Flexible Foamed Polymer Materials, Determination of Rebound Performance by the Drop Ball Method), and a water repellency test (GB / T 24218.10-2018 Textiles, Water Repellency, Part 10: Spray Test). The results are shown in Table 2.

[0076] Tatami mat performance detection results [Table 2]

[0077] From Table 2, it can be seen that the tatami mat produced in this application is flame retardant, waterproof, antibacterial, and has excellent resilience, does not emit formaldehyde, has good heat retention, and is a safe and comfortable product.

[0078] The specific examples are merely illustrative of the present application and are not intended to limit the present application, and those skilled in the art may make various changes and modifications based on the above description without departing from the technical spirit of the present application. The technical scope of the present application is not limited to the content of the specification, and should be determined based on the claims. [Explanation of symbols]

[0079] 1 EPP material 11 First EPP board 12 Second EPP board material 2 Surface layer 3 sewing thread 4 Side Surrounding Layer 5 Cushion layer

Claims

1. The EPP particles are fused together to form a plate material, and a hydrophobic antibacterial paint is applied to the surface of the plate material. The raw material for preparing the EPP particles is: 80 to 100 parts by mass of polypropylene resin, 1 to 3 parts by weight of a nucleating agent, 6 to 8 parts by weight of modified graphene composite material; 5 to 10 parts by mass of a flame retardant, 5 to 15 parts by weight of a reinforcing agent, and containing 0.5 to 1.5 parts by mass of a surfactant, The preparation raw materials of the modified graphene composite material include hydrophobic modified graphene oxide, hydrophobic antibacterial nano zinc oxide, and modified ammonium polyphosphate as a coupling agent; The EPP material is characterized in that the toughening agent comprises an ethylene-octene copolymer and an ethylene propylene diene rubber.

2. 2. The EPP material of claim 1, wherein raw materials for preparing the hydrophobically modified graphene oxide include graphene oxide, hydrazine hydrate, and octadecylamine.

3. 3. The EPP material according to claim 2, wherein the mass ratio of the graphene oxide, hydrazine hydrate, and octadecylamine is 1:0.02:(0.25-0.35).

4. 2. The EPP material of claim 1, wherein the preparation raw materials of the hydrophobic antimicrobial nano zinc oxide include nano zinc oxide, silver nitrate, and isopropyl titanium triisostearate.

5. 5. The EPP material according to claim 4, wherein the mass ratio of the nano zinc oxide, silver nitrate, and isopropyl titanium triisostearate is 1:0.15:(0.03-0.05).

6. The EPP material according to claim 1, characterized in that the raw materials for preparing the hydrophobic antibacterial paint include 40 to 50 parts by weight of a silicone-modified polyurethane resin, 2 to 3 parts by weight of a quaternary ammonium salt-based antibacterial agent, 4 to 6 parts by weight of a hydrophobic nano-titanium dioxide, 3 to 5 parts by weight of a film-forming aid, 0.03 to 0.05 parts by weight of a dispersant, 0.5 to 1 part by weight of a leveling agent, and 0.3 to 0.5 parts by weight of an antifoaming agent.

7. A method for preparing the EPP material according to any one of claims 1 to 6, comprising: the polypropylene resin, the nucleating agent, the modified graphene composite, the flame retardant, the reinforcing agent, and the surfactant are mixed, stirred, melted, kneaded, and extruded to form granules, thereby obtaining pretreated particles; the pretreated particles are added with carbon dioxide, sealed, heated, and pressurized to allow the carbon dioxide to fully penetrate the particles, and then reduced to atmospheric pressure to foam them, thereby producing EPP particles; the EPP particles are evenly placed in a mold and hot-press-welded to obtain an EPP plate; and the EPP plate is coated with a hydrophobic antibacterial paint, dried by heating, and cured to obtain an EPP material.

8. A folding mat using the EPP material according to any one of claims 1 to 6, comprising an EPP material (1), a surface layer (2), and a sewing thread (3), wherein the EPP material (1) is in the shape of a rectangular plate, the surface layer (2) covers one surface and four side walls of the EPP material (1), and the surface layer (2) and the EPP material (1) are fixedly connected by the sewing thread (3).

9. 9. The tatami mat of claim 8, wherein the material of the surface layer comprises one of grass knitting, PP knitting, modified paper knitting, cloth knitting, and rattan knitting.

Images