CN114103359A - Carpet and preparation method and application thereof - Google Patents

Carpet and preparation method and application thereof Download PDF

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Publication number
CN114103359A
CN114103359A CN202111402784.7A CN202111402784A CN114103359A CN 114103359 A CN114103359 A CN 114103359A CN 202111402784 A CN202111402784 A CN 202111402784A CN 114103359 A CN114103359 A CN 114103359A
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CN
China
Prior art keywords
parts
layer
carpet
wear
weight
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
CN202111402784.7A
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Chinese (zh)
Inventor
何锦雄
黄伟杰
柯富超
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Guangdong Fuqiang Technology Co ltd
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Guangdong Fuqiang Technology Co ltd
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Priority to CN202111402784.7A priority Critical patent/CN114103359A/en
Publication of CN114103359A publication Critical patent/CN114103359A/en
Pending legal-status Critical Current

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Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/12Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by using adhesives
    • B32B37/1284Application of adhesive
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00Ancillary operations in connection with laminating processes
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/06Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer characterised by a fibrous or filamentary layer mechanically connected, e.g. by needling to another layer, e.g. of fibres, of paper
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04Interconnection of layers
    • B32B7/12Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B60VEHICLES IN GENERAL
    • B60NSEATS SPECIALLY ADAPTED FOR VEHICLES; VEHICLE PASSENGER ACCOMMODATION NOT OTHERWISE PROVIDED FOR
    • B60N3/00Arrangements or adaptations of other passenger fittings, not otherwise provided for
    • B60N3/04Arrangements or adaptations of other passenger fittings, not otherwise provided for of floor mats or carpets
    • B60N3/042Arrangements or adaptations of other passenger fittings, not otherwise provided for of floor mats or carpets of carpets
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08GMACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G18/00Polymeric products of isocyanates or isothiocyanates
    • C08G18/06Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
    • C08G18/08Processes
    • C08G18/10Prepolymer processes involving reaction of isocyanates or isothiocyanates with compounds having active hydrogen in a first reaction step
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08GMACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G18/00Polymeric products of isocyanates or isothiocyanates
    • C08G18/06Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
    • C08G18/28Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen characterised by the compounds used containing active hydrogen
    • C08G18/40High-molecular-weight compounds
    • C08G18/42Polycondensates having carboxylic or carbonic ester groups in the main chain
    • C08G18/4236Polycondensates having carboxylic or carbonic ester groups in the main chain containing only aliphatic groups
    • C08G18/4238Polycondensates having carboxylic or carbonic ester groups in the main chain containing only aliphatic groups derived from dicarboxylic acids and dialcohols
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08GMACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G18/00Polymeric products of isocyanates or isothiocyanates
    • C08G18/06Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
    • C08G18/28Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen characterised by the compounds used containing active hydrogen
    • C08G18/40High-molecular-weight compounds
    • C08G18/42Polycondensates having carboxylic or carbonic ester groups in the main chain
    • C08G18/4266Polycondensates having carboxylic or carbonic ester groups in the main chain prepared from hydroxycarboxylic acids and/or lactones
    • C08G18/4269Lactones
    • C08G18/4277Caprolactone and/or substituted caprolactone
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08GMACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G18/00Polymeric products of isocyanates or isothiocyanates
    • C08G18/06Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
    • C08G18/28Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen characterised by the compounds used containing active hydrogen
    • C08G18/65Low-molecular-weight compounds having active hydrogen with high-molecular-weight compounds having active hydrogen
    • C08G18/66Compounds of groups C08G18/42, C08G18/48, or C08G18/52
    • C08G18/6633Compounds of group C08G18/42
    • C08G18/6637Compounds of group C08G18/42 with compounds of group C08G18/32 or polyamines of C08G18/38
    • C08G18/664Compounds of group C08G18/42 with compounds of group C08G18/32 or polyamines of C08G18/38 with compounds of group C08G18/3203
    • DTEXTILES; PAPER
    • D04BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04HMAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4326Condensation or reaction polymers
    • D04H1/435Polyesters
    • DTEXTILES; PAPER
    • D04BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04HMAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/44Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling
    • D04H1/46Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
    • D04H1/498Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres entanglement of layered webs
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00Layers arrangement
    • B32B2250/20All layers being fibrous or filamentary
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02Synthetic macromolecular fibres
    • B32B2262/0223Vinyl resin fibres
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02Synthetic macromolecular fibres
    • B32B2262/0276Polyester fibres
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02Synthetic macromolecular fibres
    • B32B2262/0292Polyurethane fibres
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00Properties of the layers or laminate
    • B32B2307/30Properties of the layers or laminate having particular thermal properties
    • B32B2307/306Resistant to heat
    • B32B2307/3065Flame resistant or retardant, fire resistant or retardant
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00Properties of the layers or laminate
    • B32B2307/50Properties of the layers or laminate having particular mechanical properties
    • B32B2307/51Elastic
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00Properties of the layers or laminate
    • B32B2307/50Properties of the layers or laminate having particular mechanical properties
    • B32B2307/536Hardness
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2605/00Vehicles
    • B32B2605/003Interior finishings
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2605/00Vehicles
    • B32B2605/08Cars

Abstract

The invention relates to a carpet and a preparation method and application thereof, wherein the carpet comprises a base material layer, a fabric layer and a wear-resistant layer which are sequentially stacked; the preparation raw materials of the fabric layer comprise the following components in parts by weight: 50-80 parts of diisocyanate, 100 parts of polyester polyol, 5-10 parts of chain extender, 3-5 parts of polyvinylidene fluoride resin and 0.1-1 part of catalyst; the wear-resistant layer comprises the following components in parts by weight: 100 parts of cross-needled polyester fiber, 8-15 parts of polyvinylidene fluoride resin and 1-20 parts of filler. The carpet disclosed by the invention has the advantages of elasticity, hardness, low VOC (volatile organic compounds), excellent stain resistance and certain flame retardant property.

Description

Carpet and preparation method and application thereof
Technical Field
The invention relates to the technical field of automotive interior trim, in particular to a carpet and a preparation method and application thereof.
Background
The rapid development of the automotive industry has made it a higher pursuit for automotive interiors, where the texture and durability of carpets is of paramount importance.
CN104371185A discloses a formula of a car carpet recoating and a preparation process thereof, wherein the formula of the disclosed car carpet recoating is prepared from the following raw materials in percentage by weight: barium sulfide, ethylene vinyl acetate, polyoxyethylene, ethylene propylene diene monomer, alkane polymer, zinc/zinc stearate, carbon black, an antioxidant and a stabilizer. Compared with the prior art, the formula of the automobile carpet recoating layer is improved, so that the automobile carpet recoating layer is not easy to deteriorate and age after being used for a long time, the acoustic performance and the related physical and chemical performance of the automobile carpet are always kept, and the operation and implementation are convenient.
CN207028418U discloses automotive carpet TIE co-extrusion composite film and automotive carpet applying the composite film, and automotive carpet TIE co-extrusion composite film comprises PA membrane, first TIE material layer, first PE membrane, second TIE material layer and PET membrane in proper order. The automobile carpet sequentially comprises a fabric layer, a second PE film, a heavy layer and the automobile carpet TIE co-extrusion composite film, wherein the PA film of the automobile carpet TIE co-extrusion composite film is connected with the heavy layer. The TIE co-extrusion composite film for the automotive carpet has the advantages of good shielding property and air tightness, and the automotive carpet has the advantages of strong sound insulation property, low VOC discharge amount and good back bonding property.
CN213007780U discloses possesses automotive carpet who adsorbs formaldehyde function, including the automotive carpet body, the automotive carpet body includes active carbon filter core, functional layer, blending surface course and PVC flexible glue slipmat, the functional layer includes active silicon filter bed and the original fiber layer of bamboo. Its automobile carpet who discloses has set up the functional layer including active silicon filter bed and the raw bamboo fiber layer, wherein, the active silicon filter bed has superstrong adsorption efficiency, raw bamboo fiber layer not only has good gas permeability, in the twinkling of an eye hydroscopicity, characteristics such as stronger wearability and good dyeability, and natural antibiotic, antibacterial, remove the mite, deodorant and ultraviolet resistance function, effectively improve whole absorption formaldehyde and antibacterial efficiency through active silicon filter bed and raw bamboo fiber layer, the active carbon filter core has been set up, improve whole dustproof through the active carbon filter core, prevent the germ, prevent formaldehyde, prevent the function of second-hand smoke, solved current automobile carpet and did not possess the function of absorption formaldehyde when using.
At present, the diversification of the automobile carpet is improved, but the development of the automobile carpet with excellent wear resistance and flame retardance and low organic gas Volatility (VOC) is very important.
Disclosure of Invention
Aiming at the defects of the prior art, the invention aims to provide a carpet, a preparation method and application thereof, wherein the carpet has the advantages of elasticity, hardness, low VOC (volatile organic compounds), excellent stain resistance and certain flame retardant property.
In order to achieve the purpose, the invention adopts the following technical scheme:
in a first aspect, the present invention provides a carpet comprising a backing layer, a face material layer and a wear layer, which are sequentially stacked;
the preparation raw materials of the fabric layer comprise the following components in parts by weight: 50-80 parts of diisocyanate, 100 parts of polyester polyol, 5-10 parts of chain extender, 3-5 parts of polyvinylidene fluoride resin and 0.1-1 part of catalyst;
the wear-resistant layer comprises the following components in parts by weight: 100 parts of cross-needled polyester fiber, 8-15 parts of polyvinylidene fluoride resin and 1-20 parts of filler.
The carpet is divided into a base material layer, a fabric layer and a wear-resistant layer, wherein polyvinylidene fluoride resin with specific weight parts is added into preparation raw materials in the wear-resistant layer, and the existence of fluorine elements can reduce the surface tension of the fabric layer and improve the anti-contamination property of the carpet; in addition, polyvinylidene fluoride resin is added into the preparation raw materials in the preparation raw materials of the fabric layer, so that the interface performance of the fabric layer is improved, the composition of the fabric layer and other adjacent layers is facilitated, and the hardness of the fabric layer can be improved.
In the invention, the preparation raw materials of the fabric layer comprise the following components in parts by weight:
the weight portion of the diisocyanate is 50-80 parts, such as 55 parts, 60 parts, 65 parts, 70 parts, 75 parts and the like.
The polyester polyol is 100 parts by weight.
The weight portion of the chain extender is 5-10 parts, such as 6 parts, 7 parts, 8 parts, 9 parts and the like.
The weight portion of the polyvinylidene fluoride resin is 3-5 portions, such as 3.2 portions, 3.5 portions, 3.8 portions, 4.0 portions, 4.5 portions, 4.8 portions and the like.
The weight portion of the catalyst is 0.1-1 portion, such as 0.2 portion, 0.4 portion, 0.6 portion, 0.8 portion and the like.
In the invention, the wear-resistant layer comprises the following components in parts by weight:
the weight portion of the cross-needled polyester fiber is 100 portions.
The weight portion of the polyvinylidene fluoride resin is 8-15 portions, such as 9 portions, 10 portions, 11 portions, 12 portions, 13 portions, 14 portions and the like.
The filler is 1-20 parts by weight, such as 2 parts, 5 parts, 8 parts, 10 parts, 12 parts, 15 parts, 18 parts and the like.
Preferably, the material of the bottom material layer comprises polyester fiber and a flame retardant. The flame retardant is arranged on the primer layer, so that the flame retardant can play a role in flame retardance and does not influence the performances of other layers.
Preferably, in the primer layer, the gram weight of the polyester fiber is 300-500g/m2E.g. 320g/m2、340g/m2、360g/m2、380g/m2、400g/m2、420g/m2、440g/m2、460g/m2、480g/m2And the like.
Preferably, the polyester fibers comprise ethylene-vinyl acetate copolymer and/or polyurethane, further preferably a combination of ethylene-vinyl acetate copolymer and polyurethane.
Preferably, the raw materials for preparing the fabric layer further comprise an auxiliary agent.
Preferably, the auxiliary agent comprises any one of or a combination of at least two of an anti-aging agent, a softening agent, a cell opener or a stabilizer, wherein a typical but non-limiting combination comprises: combinations of anti-aging agents and softeners, combinations of softeners, cell openers and stabilizers, combinations of anti-aging agents, softeners, cell openers and stabilizers, and the like.
Preferably, the diisocyanate comprises any one of hexamethylene diisocyanate, cyclohexanedimethylene diisocyanate, diphenylmethane diisocyanate or p-phenylene diisocyanate or a combination of at least two thereof, wherein typical but non-limiting combinations include: hexamethylene diisocyanate and cyclohexane dimethylene diisocyanate, diphenylmethane diisocyanate, and p-phenylene diisocyanate, hexamethylene diisocyanate, cyclohexane dimethylene diisocyanate, diphenylmethane diisocyanate, and p-phenylene diisocyanate, and the like.
Preferably, the polyester polyol comprises any one or a combination of at least two of polycaprolactone polyol, polyhexamethylene adipate polyol, or polyethylene adipate polyol, wherein typical but non-limiting combinations include: a combination of polycaprolactone polyol and polyhexamethylene adipate polyol, a combination of polyhexamethylene adipate polyol and polyethylene adipate polyol, a combination of polycaprolactone polyol, polyhexamethylene adipate polyol, and polyethylene adipate polyol, and the like.
Preferably, the polyester polyols have hydroxyl numbers of 50-70mg KOH/g, 52KOH/g, 54KOH/g, 56KOH/g, 58KOH/g, 60KOH/g, 62KOH/g, 64KOH/g, 66KOH/g, 68KOH/g, etc., e.g., a number average molecular weight of 1500-3000g/mol, e.g., 1600g/mol, 1800g/mol, 2000g/mol, 2200g/mol, 2400g/mol, 2600g/mol, 2800g/mol, etc.
Preferably, the chain extender comprises any one of, or a combination of at least two of, 1, 4-butanediol, 1, 6-hexanediol, or ethylenediamine, with typical but non-limiting combinations including: combinations of 1, 4-butanediol and 1, 6-hexanediol, combinations of 1, 6-hexanediol and ethylenediamine, combinations of 1, 4-butanediol, 1, 6-hexanediol and ethylenediamine, and the like.
Preferably, the catalyst comprises any one of or a combination of at least two of tetra-N-butyltin, stannous chloride, stannous octoate, hydroxytrimethyltin, dibutyl tin dilaurate, N-methylmorpholine, or N, N' -dimorpholinyl diethyl ether, wherein typical but non-limiting combinations include: a combination of tetra-N-butyltin, stannous chloride and stannous octoate, a combination of stannous octoate, hydroxytrimethyltin, dibutyl tin dilaurate and N-methylmorpholine, a combination of stannous octoate, hydroxytrimethyltin, dibutyl tin dilaurate, N-methylmorpholine and N, N' -dimorpholinyl diethyl ether, and the like.
Preferably, the filler comprises ethylene propylene diene monomer rubber and/or silicone rubber.
Preferably, an adhesive layer containing activated carbon particles is arranged between the wear-resistant layer and the fabric layer. The invention separately arranges the activated carbon particles with adsorption in the adhesive layer, so that the activated carbon particles are not arranged in each layer of the carpet, thereby saving raw materials and improving the absorption of organic volatile gas.
Preferably, the thickness of the primer layer is 15-25mm, such as 16mm, 18mm, 20mm, 22mm, 24mm, and the like.
Preferably, the thickness of the shell fabric layer is 10-15mm, such as 11mm, 12mm, 13mm, 14mm, and the like.
Preferably, the wear resistant layer has a thickness of 5-15mm, such as 6mm, 8mm, 10mm, 12mm, 14mm, etc.
In a second aspect, the present invention provides a method for preparing a carpet according to the first aspect, the method comprising the steps of:
step 1, respectively opening and mixing preparation raw materials of a base material layer and a wear-resistant layer, carding, then laying into at least two fiber nets, and performing needling reinforcement to obtain the base material layer and the wear-resistant layer;
step 2, mixing diisocyanate, polyester polyol, a chain extender and a catalyst to form polyurethane, melting and mixing the polyurethane with polyvinylidene fluoride resin, carding, laying into at least two fiber nets, and performing needling reinforcement to obtain a fabric layer;
and 3, sequentially compounding the base material layer, the fabric layer and the wear-resistant layer to obtain the carpet.
Preferably, in the step 1, the needling reinforcement includes pre-needling and secondary needling.
Preferably, the pre-needling depth is 8-10mm, such as 8.2mm, 8.5mm, 8.8mm, 9.2mm, 9.5mm, 9.8mm, etc., and the density of pre-needling is 50-200 needles/cm2E.g. 80 needles/cm2100 needles/cm2120 needles/cm2150 needles/cm2180 needles/cm2And the like.
Preferably, the depth of the secondary needling is 6-8mm, such as 6.2mm, 6.4mm, 6.6mm, 6.8mm, 7.0mm, 7.2mm, 7.4mm, 7.6mm, etc., and the density of the pre-needling is 100-2E.g. 110 needles/cm2120 needles/cm2130 needles/cm2140 needles/cm2And the like.
Preferably, in step 2, the preparation method of the polyurethane specifically includes: polyester polyol and diisocyanate are mixed and react under the action of a catalyst to generate polyurethane prepolymer, and then the polyurethane prepolymer forms polyurethane under the action of a chain extender.
Preferably, the fabric layer and the wear-resistant layer are compounded through an adhesive layer containing activated carbon particles.
In a third aspect, the present invention provides a use of the carpet of the second aspect in an automobile.
Compared with the prior art, the invention has the following beneficial effects:
the carpet disclosed by the invention has the advantages of elasticity, hardness, low VOC (volatile organic compounds), excellent stain resistance and certain flame retardant property. The Young modulus of the carpet is between 6.3 and 6.5MPa, the elongation at break is between 370 and 402 percent, and the TVOC is 2862 mu g/m3Within, the anti-contamination performance is 1-2 grade.
Detailed Description
The technical solution of the present invention is further explained by the following embodiments. It should be understood by those skilled in the art that the examples are only for the understanding of the present invention and should not be construed as the specific limitations of the present invention.
Example 1
The embodiment provides a carpet, which comprises a base material layer, a fabric layer, an adhesive layer and a wear-resistant layer which are sequentially stacked;
(1) the thickness of the primer layer is 20mm, and the primer layer comprises the following specific components:
ethylene-vinyl acetate copolymer: 70 parts by weight of EVA210W (DuPont) with the gram weight of 400g/m2
Polyurethane: 30 parts by weight of a polyurethane elastomer sold in Basff under the trade name 1160A13P and a gram weight of 400g/m2
Flame retardant: 12 parts by weight of polyurethane flame retardant, which is purchased from Shanghai Polyqian New Material development Co., Ltd, model CZ.
(2) The thickness of the fabric layer is 12mm, and the fabric layer comprises the following components:
diisocyanate: 40 parts by weight of hexamethylene diisocyanate and 20 parts by weight of p-phenylene diisocyanate;
polyester polyol: 100 parts by weight of polycaprolactone polyol, available from Shanghai Michelin Biochemical technology, Inc.; hydroxyl value is 65mg KOH/g, number average molecular weight is 2000 g/mol;
chain extender: 8 parts by weight of 1, 4-butanediol;
polyvinylidene fluoride resin: 4 parts by weight of a compound with a trade name of S63756-1g, which is purchased from Shanghai Yuan Ye Biotech Co., Ltd;
catalyst: 0.5 part by weight of tetra-n-butyltin.
An anti-aging agent: 3 parts by weight of 2, 7-dibromo-9, 9 dimethylacridine;
a stabilizer: 4 parts by weight of ultraviolet absorbent UV-1084.
(3) The wear-resistant layer is 8mm in thickness and specifically comprises the following components:
cross-needled polyester fibers: 100 parts by weight of a model 2420K purchased from plastic chemical Co., Ltd, Dongguan city;
polyvinylidene fluoride resin: 10 parts by weight of a compound (S63756-1 g) which is purchased from Shanghai source leaf Biotech Co., Ltd;
filling: 10 parts by weight of ethylene propylene diene monomer, available from Yongkui science and technology Limited in Hubei;
5 parts by weight of silicon rubber purchased from alatin and having the grade of S112243-2.5 kg;
(4) adhesive layer: the thickness is 1mm, specifically as follows;
20 parts by weight of activated carbon granules and 100 parts of polypropylene melt adhesive (available from Nantong Runfeng petrochemical Co., Ltd.).
The preparation method of the carpet comprises the following steps:
step 1, respectively opening and mixing preparation raw materials of a base material layer and a wear-resistant layer, carding, then laying into at least two fiber nets, and then carrying out pre-needling and secondary needling reinforcement to obtain the base material layer and the wear-resistant layer;
step 2, mixing polyester polyol and diisocyanate, reacting for 5 hours at 75 ℃ under the action of a catalyst to generate polyurethane prepolymer, and reacting for 4.5 hours at 130 ℃ under the action of a chain extender to generate polyurethane;
then melting and mixing with polyvinylidene fluoride resin, an anti-aging agent and a stabilizer, carding and then laying into at least two layers of fiber nets;
then pre-needling reinforcement is carried out, the depth of the pre-needling is 9mm, and the density of the pre-needling is 100 needles/cm2Then, secondary needling is carried out for reinforcement, the depth of the secondary needling is 7mm, and the density of the pre-needling is 120 needles/cm2Obtaining a fabric layer;
and 3, sequentially compounding the base material layer, the fabric layer, the adhesive layer and the wear-resistant layer to obtain the carpet.
Example 2
The embodiment provides a carpet, which comprises a base material layer, a fabric layer, an adhesive layer and a wear-resistant layer which are sequentially stacked;
(1) the thickness of the primer layer is 15mm, and the primer layer comprises the following specific components:
ethylene-vinyl acetate copolymer: 70 parts by weight of EVA210W (DuPont) with the gram weight of 400g/m2
Polyurethane: 30 parts by weight of a polyurethane elastomer sold in Basff under the trade name 1160A13P and a gram weight of 400g/m2
Flame retardant: 12 parts by weight of polyurethane flame retardant, which is purchased from Shanghai Polyqian New Material development Co., Ltd, model CZ.
(2) The thickness of the fabric layer is 15mm, and the fabric layer comprises the following components:
the fabric layer is prepared from the following raw materials in parts by weight:
diisocyanate: 50 parts by weight of hexamethylene diisocyanate;
polyester polyol: 100 parts by weight of polycaprolactone polyol, purchased from Shanghai Michelin Biochemical technology, Inc.; hydroxyl value is 65mg KOH/g, number average molecular weight is 2000 g/mol;
10 parts of a chain extender, 1, 6-hexanediol;
polyvinylidene fluoride resin: 5 parts by weight of a reaction product of (B),
catalyst: 1 part by weight of stannous octoate.
An anti-aging agent: 3 parts by weight of 2, 7-dibromo-9, 9 dimethylacridine;
a stabilizer: 4 parts by weight of ultraviolet absorbent UV-1084.
(3) The wear-resistant layer is 15mm in thickness and specifically comprises the following components:
cross-needled polyester fibers: 100 parts by weight of a model 2420K purchased from plastic chemical Co., Ltd, Dongguan city;
polyvinylidene fluoride resin: 8 parts by weight of a product which is purchased from Shanghai source leaf Biotechnology Co., Ltd and is sold as S63756-1 g;
filling: 3 parts by weight of ethylene propylene diene monomer, purchased from Yongkui technology Limited in Hubei;
2 parts by weight of silicon rubber purchased from alatin and having the grade of S112243-2.5 kg;
(4) adhesive layer: the thickness is 1 mm;
20 parts by weight of activated carbon granules and 100 parts of polypropylene melt adhesive (available from Nantong Runfeng petrochemical Co., Ltd.).
The preparation method of the carpet comprises the following steps:
step 1, respectively opening and mixing preparation raw materials of a base material layer and a wear-resistant layer, carding, then laying into at least two fiber nets, and then carrying out pre-needling and secondary needling reinforcement to obtain the base material layer and the wear-resistant layer;
step 2, mixing polyester polyol and diisocyanate, reacting for 5 hours at 75 ℃ under the action of a catalyst to generate polyurethane prepolymer, and reacting for 4.5 hours at 130 ℃ under the action of a chain extender to generate polyurethane;
then melting and mixing with polyvinylidene fluoride resin, an anti-aging agent and a stabilizer, carding and then laying into at least two layers of fiber nets;
then pre-needling reinforcement is carried out, the depth of the pre-needling is 8mm, and the density of the pre-needling is 200 needles/cm2Then, secondary needling is carried out for reinforcement, the depth of the secondary needling is 6mm, and the density of the pre-needling is 150 needles/cm2Obtaining a fabric layer;
and 3, sequentially compounding the base material layer, the fabric layer, the adhesive layer and the wear-resistant layer to obtain the carpet.
Example 3
The embodiment provides a carpet, which comprises a base material layer, a fabric layer, an adhesive layer and a wear-resistant layer which are sequentially stacked;
(1) the thickness of the primer layer is 25mm, and the primer layer comprises the following specific components:
ethylene-vinyl acetate copolymer: 70 parts by weight of EVA210W (DuPont) with the gram weight of 400g/m2
Polyurethane: 30 parts by weight of a polyurethane elastomer sold in Basff under the trade name 1160A13P and a gram weight of 400g/m2
Flame retardant: 12 parts by weight of polyurethane flame retardant, which is purchased from Shanghai Polyqian New Material development Co., Ltd, model CZ.
(2) The thickness of the fabric layer is 10mm, and the fabric layer comprises the following components:
the fabric layer is prepared from the following raw materials in parts by weight:
diisocyanate: 80 parts by weight of diphenylmethane diisocyanate;
polyester polyol: 100 parts by weight of polyhexamethylene adipate polyol, available from Hubei Wan pharmaceutical Co., Ltd;
chain extender: 10 parts of ethylenediamine;
polyvinylidene fluoride resin: 3 parts by weight of a compound with a trade name of S63756-1g, which is purchased from Shanghai Yuan Ye Biotech Co., Ltd;
catalyst: 0.1 part by weight of N, N' -dimorpholinyl diethyl ether.
An anti-aging agent: 3 parts by weight of 4,4' -diaminodiphenylmethane;
a stabilizer: 4 parts by weight of ultraviolet absorbent UV-1084.
(3) The thickness of the wear-resistant layer is 5mm, and the wear-resistant layer comprises the following components:
cross-needled polyester fibers: 100 parts by weight of a model 2420K purchased from plastic chemical Co., Ltd, Dongguan city;
polyvinylidene fluoride resin: 15 parts by weight of a compound (S63756-1 g) which is purchased from Shanghai source leaf Biotech Co., Ltd;
filling: 10 parts by weight of ethylene propylene diene monomer, available from Yongkui science and technology Limited in Hubei;
10 parts by weight of silicon rubber purchased from alatin and having the grade of S112243-2.5 kg;
(4) adhesive layer: the thickness is 1 mm;
20 parts by weight of activated carbon granules and 100 parts of polypropylene melt adhesive (available from Nantong Runfeng petrochemical Co., Ltd.).
The preparation method of the carpet comprises the following steps:
step 1, respectively opening and mixing preparation raw materials of a base material layer and a wear-resistant layer, carding, then laying into at least two fiber nets, and then carrying out pre-needling and secondary needling reinforcement to obtain the base material layer and the wear-resistant layer;
step 2, mixing polyester polyol and diisocyanate, reacting for 5 hours at 75 ℃ under the action of a catalyst to generate polyurethane prepolymer, and reacting for 4.5 hours at 130 ℃ under the action of a chain extender to generate polyurethane;
then melting and mixing with polyvinylidene fluoride resin, an anti-aging agent and a stabilizer, carding and then laying into at least two layers of fiber nets;
then pre-needling reinforcement is carried out, the depth of the pre-needling is 10mm, and the density of the pre-needling is 50 needles/cm2Then secondary needling is carried out for reinforcement, the depth of the secondary needling is 8mm, and the density of the pre-needling is 100 needles/cm2Obtaining a fabric layer;
and 3, sequentially compounding the base material layer, the fabric layer, the adhesive layer and the wear-resistant layer to obtain the carpet.
Example 4
This example is different from example 1 in that an adhesive layer is not provided, and a raw material for preparing the adhesive layer is melt-mixed with polyurethane together with a polyvinylidene fluoride resin to form a fabric layer, and the rest is the same as example 1.
Examples 5 to 6
Examples 5 to 6 are different from example 1 in that the parts by weight of the polyvinylidene fluoride resin in the abrasion resistant layer are 8 parts (example 5) and 15 parts (example 6), respectively, and the rest is the same as example 1.
Comparative examples 1 to 2
Comparative examples 1-2 are different from example 1 in that the parts by weight of the polyvinylidene fluoride resin in the abrasion resistant layer are 5 parts (comparative example 1) and 20 parts (comparative example 2), respectively, and the rest is the same as example 1.
Performance testing
Examples 1-6 and comparative examples 1-2 were tested as follows:
(1) VOC performance: testing is carried out according to HJ/T400-2007 method for sampling and measuring volatile organic compounds and aldehyde ketone substances in the automobile, which is indicated by GN/T27630-2011 guideline for evaluating air quality in the automobile for passenger use;
(2) mechanical properties: testing the mechanical property on a universal material tester according to GB/T528-2009;
(3) stain resistance: testing the anti-contamination performance of the TPU film to an oil marking pen according to the specification of JGT 304-2011 standard; grade 1 indicates removability with dry lint-free cotton cloth, grade 2 indicates removability with a 1% neutral aqueous weak cleaner, and grade 3 indicates removability with a citrus-based cleaner.
The test results are summarized in table 1.
TABLE 1
Figure BDA0003371636580000131
As can be seen from the analysis of the data in Table 1, the Young modulus of the carpet of the present invention is between 6.3 MPa and 6.5MPa, the elongation at break is between 370-402%, and the TVOC is 2862 μ g/m3The antifouling property is within 1-2 grade, and the antifouling paint has elasticity, hardness, low VOC and excellent antifouling property.
As can be seen from the analysis of comparative examples 1-2 and examples 5-6, comparative examples 1-2 were inferior in performance to examples 5-6, comparative example 1 was inferior in stain resistance, comparative example 2 was inferior in elasticity, and TVOC value was higher, demonstrating that the carpet performance was better formed with the weight part of the polyvinylidene fluoride resin in the range of 8-15 parts.
Analysis of example 4 and example 1 shows that the performance of example 4 is inferior to that of example 1, wherein the TVOC value is significantly improved, which proves that the performance of the fabric layer can not be lost by separately disposing the adsorption material in the hot melt adhesive layer, and the adsorption material can contact both the fabric layer and the wear-resistant layer, thereby facilitating the absorption of volatile gas.
The present invention is illustrated in detail by the examples described above, but the present invention is not limited to the details described above, i.e., it is not intended that the present invention be implemented by relying on the details described above. It should be understood by those skilled in the art that any modification of the present invention, equivalent substitutions of the raw materials of the product of the present invention, addition of auxiliary components, selection of specific modes, etc., are within the scope and disclosure of the present invention.

Claims (10)

1. The carpet is characterized by comprising a base material layer, a fabric layer and a wear-resistant layer which are sequentially stacked;
the preparation raw materials of the fabric layer comprise the following components in parts by weight: 50-80 parts of diisocyanate, 100 parts of polyester polyol, 5-10 parts of chain extender, 3-5 parts of polyvinylidene fluoride resin and 0.1-1 part of catalyst;
the wear-resistant layer comprises the following components in parts by weight: 100 parts of cross-needled polyester fiber, 8-15 parts of polyvinylidene fluoride resin and 1-20 parts of filler.
2. The carpet of claim 1, wherein the material of the backing layer comprises polyester fibers and a flame retardant;
preferably, in the primer layer, the gram weight of the polyester fiber is 300-500g/m2
Preferably, the polyester fibers comprise ethylene-vinyl acetate copolymer and/or polyurethane.
3. The carpet of claim 1 or 2, characterized in that the preparation raw material of the fabric layer further comprises an auxiliary agent;
preferably, the auxiliary agent comprises any one or a combination of at least two of an anti-aging agent, a softening agent, a pore opening agent or a stabilizing agent.
4. The carpet of any of claims 1-3, wherein the diisocyanate comprises any one or a combination of at least two of hexamethylene diisocyanate, cyclohexane dimethylene diisocyanate, diphenylmethane diisocyanate, or p-phenylene diisocyanate;
preferably, the polyester polyol comprises any one of or a combination of at least two of polycaprolactone polyol, polyhexamethylene adipate polyol, or polyethylene adipate polyol;
preferably, the hydroxyl value of the polyester polyol is 50-70mg KOH/g, and the number average molecular weight is 1500-3000 g/mol;
preferably, the chain extender comprises any one of 1, 4-butanediol, 1, 6-hexanediol or ethylenediamine or a combination of at least two thereof;
preferably, the catalyst comprises any one of tetra-N-butyltin, stannous chloride, stannous octoate, hydroxy trimethyltin, dibutyl tin dilaurate, N-methyl morpholine or N, N' -bis morpholino diethyl ether or a combination of at least two thereof.
5. The carpet of any of claims 1-4, characterized in that in the wear layer, the filler comprises ethylene propylene diene monomer rubber and/or silicone rubber;
preferably, an adhesive layer containing activated carbon particles is arranged between the wear-resistant layer and the fabric layer.
6. Carpet as claimed in any of the claims 1-4, characterized in that the thickness of the backing layer is 15-25 mm;
preferably, the thickness of the fabric layer is 10-15 mm;
preferably, the wear resistant layer has a thickness of 5-15 mm.
7. A method of making a carpet as claimed in any one of claims 1 to 6, comprising the steps of:
step 1, respectively opening and mixing preparation raw materials of a base material layer and a wear-resistant layer, carding, then laying into at least two fiber nets, and performing needling reinforcement to obtain the base material layer and the wear-resistant layer;
step 2, mixing diisocyanate, polyester polyol, a chain extender and a catalyst to form polyurethane, melting and mixing the polyurethane with polyvinylidene fluoride resin, carding, laying into at least two fiber nets, and performing needling reinforcement to obtain a fabric layer;
and 3, sequentially compounding the base material layer, the fabric layer and the wear-resistant layer to obtain the carpet.
8. The manufacturing method according to claim 7, wherein in the step 1, the needle punching reinforcement includes pre-needle punching and secondary needle punching;
preferably, the depth of the pre-needling is 8-10mm, and the density of the pre-needling is 50-200 needles/cm2
Preferably, the depth of the secondary needling is 6-8mm, and the density of the pre-needling is 100-150 needles/cm2
9. The method according to claim 7 or 8, wherein in the step 2, the method for preparing polyurethane specifically comprises: mixing polyester polyol and diisocyanate, reacting under the action of a catalyst to generate polyurethane prepolymer, and then forming polyurethane under the action of a chain extender;
preferably, the fabric layer and the wear-resistant layer are compounded through an adhesive layer containing activated carbon particles.
10. Use of a carpet according to any of claims 1 to 6 in an automobile.
CN202111402784.7A 2021-11-24 2021-11-24 Carpet and preparation method and application thereof Pending CN114103359A (en)

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JP2000071844A (en) * 1998-09-03 2000-03-07 Nissan Motor Co Ltd Sound insulating structure
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CN107405860A (en) * 2015-02-20 2017-11-28 肖氏工业集团公司 Resiliently-mounted floor product and its manufacture method
CN109924837A (en) * 2017-12-19 2019-06-25 天津市江美科技有限公司 A kind of anti-carpets
CN110139954A (en) * 2016-12-27 2019-08-16 Sabic环球技术有限责任公司 Fiber comprising fibrillation reinforcing material
KR20200052817A (en) * 2018-11-07 2020-05-15 시피엘 뉴 머티어리얼 테크놀러지 컴퍼니 리미티드 Composite fabric as well as preparation method and application thereof
CN112239528A (en) * 2020-09-18 2021-01-19 东莞市雄林新材料科技股份有限公司 Environment-friendly TPU film for table mat and preparation method thereof

Patent Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5601910A (en) * 1995-04-18 1997-02-11 E. I. Du Pont De Nemours And Company Rug underlay substantially impervious to liquids
JP2000071844A (en) * 1998-09-03 2000-03-07 Nissan Motor Co Ltd Sound insulating structure
CN101046063A (en) * 2007-04-24 2007-10-03 江苏中联地毯有限公司 Composite adhered automobile carpet and its making process
CN107405860A (en) * 2015-02-20 2017-11-28 肖氏工业集团公司 Resiliently-mounted floor product and its manufacture method
CN110139954A (en) * 2016-12-27 2019-08-16 Sabic环球技术有限责任公司 Fiber comprising fibrillation reinforcing material
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