CN120422547B - A polymer hydrolysis-resistant composite carpet and its preparation method and application - Google Patents
A polymer hydrolysis-resistant composite carpet and its preparation method and applicationInfo
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- CN120422547B CN120422547B CN202510928531.5A CN202510928531A CN120422547B CN 120422547 B CN120422547 B CN 120422547B CN 202510928531 A CN202510928531 A CN 202510928531A CN 120422547 B CN120422547 B CN 120422547B
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Abstract
The invention provides a high polymer hydrolysis-resistant composite carpet, and a preparation method and application thereof, and belongs to the field of high polymer carpets. According to the invention, polyamide 6 is used as a matrix, the compatibility is enhanced through the hydrophobic modification of the organic silicon resin and the compatilizer, the fiber hydrophobic and mechanical property balance is realized by combining the precise temperature control spinning and stretching puffing process, the multilayer composite structure design is adopted, the materials of all layers cooperatively play the waterproof, bonding and supporting functions, and the optimized tufting, coating and laminating processes are matched, so that the carpet has excellent performances in hydrolysis resistance, wear resistance, weather resistance, color fastness and the like, can adapt to various complex environments, and has practicability and durability.
Description
Technical Field
The invention relates to the field of polymer carpets, in particular to a polymer hydrolysis-resistant composite carpet, and a preparation method and application thereof.
Background
With the gradual development of modern home soft wear and automotive interiors, carpets have become important decorative materials in different industrial fields. The carpet is often worn in use environment and needs to be cleaned frequently, so that the service life of the carpet is greatly reduced, latex is coated on the back and dried in the conventional carpet production process to form a glue film on the back of the carpet through the latex, and the fluff is firmly adhered to the base cloth, so that the carpet is not easy to fall off and pill in the use process. With the increasing strictness of global environmental regulations and the rising of consumer health consciousness, traditional solvent-based latex is gradually replaced by aqueous latex because of containing Volatile Organic Compounds (VOCs), which are easy to generate pungent smell and cause potential harm to human health. However, the characteristic of aqueous latex using water as a dispersion medium causes significant defects in water resistance, and becomes a key bottleneck for restricting the improvement of the performance of carpet products.
Therefore, the preparation of a carpet material by selecting a water-resistant material becomes a first choice, for example, patent application CN110789186a discloses a carpet with good wear resistance and water resistance, which mainly comprises a carpet body, wherein the carpet body mainly comprises a base cloth layer, a waterproof layer formed by uniformly coating silica gel is arranged on the lower surface of the base cloth layer, a non-woven fabric layer is adhered and fixed on the lower surface of the waterproof layer, a latex layer formed by latex is coated on the upper surface of the base cloth layer, diatom ooze is adhered and fixed on the latex layer, a chemical fiber textile cloth layer is uniformly coated on the upper surface of the chemical fiber textile cloth layer, a waterproof membrane layer is sprayed on the upper surface of the chemical fiber textile cloth layer, and a flexible decorative layer is adhered and covered on the upper surface of the waterproof membrane layer.
The method of adding the waterproof layer in the carpet layer structure is widely used in the current carpet industry, but the mechanical property and the like of the waterproof layer are reduced due to poor compatibility between the waterproof layer and other bonding layers or functional layers, and the material of part of the waterproof layer is not environment-friendly, so that the odor and the environment-friendliness of the carpet are enhanced, and the synchronous improvement of the hydrolysis resistance of the carpet is a development trend at present on the basis of maintaining the original wear resistance, corrosion resistance and other characteristics of the carpet.
In summary, the carpet must be cleaned during use, but because it is necessary to replace the conventional common latex with the aqueous latex having low odor in order to meet the environmental requirements of the existing tufted carpet, the water resistance of the tufted carpet is greatly reduced. Therefore, tufted carpets are poor in hydrolysis resistance, while the mechanical properties, corrosion resistance, stability, etc. of tufted carpets remain to be solved.
Disclosure of Invention
Aiming at the problems, the invention provides a high polymer hydrolysis-resistant composite carpet, a preparation method and application thereof, wherein hydrolysis-resistant hydrophobic fiber bundles are prepared, the hydrophobic fiber bundles are tufted into a hydrophobic pile layer, and then latex with hydrophobicity is continuously coated into an adhesive layer, so that the hydrolysis resistance, mechanical properties and the like of the carpet are synergistically improved.
The invention provides a high-molecular hydrolysis-resistant composite carpet, which comprises a bottom layer, a second supporting layer, a reinforcing layer, a first supporting layer, an adhesive layer, a base cloth layer and a hydrophobic pile layer from bottom to top, wherein the hydrophobic pile layer is formed by mixing a first hydrophobic organosilicon material and a first compatilizer which are mixed by polyamide 6, melting and spinning to prepare a hydrophobic fiber bundle, tufting the hydrophobic fiber bundle onto the base cloth layer through a tufting machine, coating a second hydrophobic organosilicon material and a second compatilizer which are mixed by aqueous polyurethane foaming emulsion on the bottom of the base cloth layer to obtain the adhesive layer, and continuously and sequentially compounding the first supporting layer, the reinforcing layer, the second supporting layer and the bottom layer to prepare the high-molecular hydrolysis-resistant composite carpet;
The heat-resistant dimensional stability of the polymer hydrolysis-resistant composite carpet is 0.51-0.72% in the warp direction and 0.57-0.78% in the weft direction, and the dimensional stability in the soaking direction is 0.57-0.76% in the warp direction and 0.62-0.72% in the weft direction;
The color fastness to water of the macromolecule hydrolysis-resistant composite carpet is 4.5-5 grade, the light color fastness is more than or equal to 4 grade, and the color fastness after the testing of the washing-resistant agent and gasoline is more than or equal to 4 grade;
The pile cluster pulling-out force of the polymer hydrolysis-resistant composite carpet is 21-25N, the pile cluster pulling-out force after soaking is 20-25N, the wear-resistant turns are not less than 2900 turns and do not leak, and the stripping force is 28-34N.
Further, the thickness of the polymer hydrolysis-resistant composite carpet is 10-14mm, the pile height is 3-5mm, and the pile shape is cut pile.
Further, the polymer hydrolysis-resistant composite carpet has no cracks, delamination, foaming, shrinkage, deformation and pungent odor after being placed for 24 hours at the temperature of-40 ℃, 168 hours at the temperature of 90 ℃ and irradiated under illumination.
The invention also provides a preparation method of the polymer hydrolysis-resistant composite carpet, which comprises the following steps:
Step 1, adding polyamide 6, a compatilizer I, an organosilicon material I and a color masterbatch into a high-speed mixer, stirring and mixing to obtain a mixture, extruding and spinning the mixture through a screw extruder, melt-blending the mixture in the screw extruder, spinning the mixture through a spinneret plate, and rapidly cooling the mixture to obtain hydrophobic fiber;
Step 2, oiling the hydrophobic fiber, carrying out primary stretching and secondary stretching on the oiled hydrophobic fiber, carrying out jet puffing on the stretched hydrophobic fiber, cooling by a cooling roller, continuously knotting the hydrophobic fiber in a spinning network device, and winding by a winding machine to obtain a hydrophobic fiber bundle;
Step 3, arranging a non-woven base fabric, tufting the hydrophobic fiber bundles onto the non-woven base fabric to obtain a hydrophobic pile layer and a base fabric layer;
Step 4, stirring the aqueous polyurethane foaming emulsion, the compatilizer II and the organosilicon material II, coating the mixture on the bottom of the base cloth layer, and drying the mixture to obtain an adhesive layer;
and 5, continuing to spray the film adhesive to bond the polyethylene-polyamide-polyethylene film (PEPAPE) at the bottom of the bonding layer, continuing to spray the film adhesive to bond the needled base felt, cooling to obtain a first supporting layer and a reinforcing layer, continuing to spray the film adhesive to bond the polyethylene-polyamide-polyethylene film (PEPAPE) at the bottom of the reinforcing layer, continuing to spray the film adhesive to bond the non-woven base fabric, cooling to obtain a second supporting layer and a bottom layer, and finally obtaining the high-molecular hydrolysis-resistant composite carpet.
Further, the speed of the high-speed mixer in the step 1 is 600-800rpm, and the mixing time of the high-speed mixer is 2-4min.
Further, the mass ratio of the polyamide 6, the compatibilizer 1, the silicone material one, and the color master in the step 1 is (80:5:8:2) - (80:8:10:3).
Further, the first compatibilizer in the step 1 is a maleic anhydride grafted polyamide.
Further, the first silicone material in the step 1 is a polyester modified silicone resin.
Further, the processing temperature of the screw extruder in the step 1 is 220-260 ℃ and is divided into four temperature areas, wherein the temperature of the first temperature area is 220-230 ℃, the temperature of the second temperature area is 240-250 ℃, the temperature of the third temperature area is 250-260 ℃ and the temperature of the fourth temperature area is 240-250 ℃.
Further, the number of holes of the spinneret plate in the step 1 is 50-60, and the spinneret plate is a trilobal spinneret plate.
Further, the temperature of the air cooling in the step 1 is 15-25 ℃.
Further, the oiling type in the step 2 is monohydroxy silicone oil, and the oiling rate is 0.6-0.8%.
Further, the temperature of the primary stretching in the step 2 is 80-90 ℃ and the stretching multiplying power is 1.01.
Further, the temperature of the secondary stretching in the step 2 is 170-190 ℃, and the stretching multiplying power is 2.3.
Further, in the step 2, the puffing temperature is 170-200 ℃ and the nozzle pressure of the air injection is 4-5bar.
Further, the temperature of the cooling roller in the step 2 is 20-25 ℃ and the rotating speed is 30-40rpm.
Further, the number of knots in the step 2 is (25-27) ± 1, and the gas pressure of the spinning network is 3-4bar.
Further, the total crimp degree of the hydrophobic fiber bundles in the step 2 is 15-18%, the fineness is 1500-1900D, and the number of holes is 50-60.
Further, the gram weight of the nonwoven base fabric in the step 3 is 120-140gsm, and the nonwoven base fabric is polyethylene terephthalate (PET) nonwoven base fabric.
Further, the tufting in the step 3 has a stitch length of 1/10 or 5/64, a weft knitting density of 39.37 needles/cm or 50.39 needles/cm, a warp knitting density of 50-60 needles/cm, a needle penetration depth of 5-6mm, and a needle frequency of 800-1000rpm.
Further, the mass ratio of the aqueous polyurethane foam latex, the compatilizer II and the organosilicon material II in the step 4 is (4:1:1) - (4:1:2).
Further, the foaming ratio of the aqueous polyurethane foaming latex in the step 4 is 2.0-3.0 times.
Further, the second compatibilizer in the step 4 is a maleic anhydride grafted polyolefin elastomer.
Further, the second organosilicon material in the step 4 is a polyester modified organosilicon resin.
Further, the stirring speed in the step 4 is 600-800rpm, and the stirring time is 8-10min.
Further, the coating speed in the step 4 is 8-15m/min.
Further, the temperature of the drying in the step 4 is 130-190 ℃, and the drying time is 2-4min.
Further, the grammage of the adhesive layer in the step 4 is 50-130gsm.
Further, the speed of the film coating in the step 5 is 3-4m/min, and the temperature of the film coating is 230-250 ℃.
Further, in the step 5, the binders are polyethylene, and the grammage is 200-500gsm.
Further, the needled bottom felt in the step 5 is a polyethylene terephthalate (PET) needled bottom felt.
Further, the first supporting layer in the step 5 has a grammage of 100-300gsm.
Further, the grammage of the reinforcing layer in the step 5 is 300-400gsm.
Further, the nonwoven substrate in the step 5 is a polyethylene terephthalate (PET) nonwoven substrate.
Further, the second supporting layer in the step 5 has a grammage of 100-300gsm.
Further, the grammage of the bottom layer in step 5 is 200-300gsm.
The invention also provides an automobile carpet which is prepared from the polymer hydrolysis-resistant composite carpet.
The invention has the beneficial effects that:
1. According to the invention, polyamide 6 is used as a matrix, polyester modified organic silicon resin is mixed, and a compatilizer is adopted to improve the compatilizer of the polyamide 6 and the organic silicon resin, so that the problem of incompatibility caused by organic silicon materials is weakened, wherein the polyester modified organic silicon resin migrates to the surface of the fiber to form a low surface energy structure, the hydrophobic property of the fiber is endowed, the interfacial compatibility of the polyamide 6 and the organic silicon resin is enhanced by maleic anhydride grafted polyamide, the material phase separation is avoided, the stability of the mechanical property of the fiber is ensured, the hydrophobic problem of a pile layer is improved, the polyamide 6 and the organic silicon material are melted and spun through a specific mixing temperature, the full mixing of the polyamide 6 and the organic silicon material is ensured at the temperature, the molecular structure of the polyamide 6 and the organic silicon material is not damaged, meanwhile, a trilobal spinneret plate is adopted to be matched with an air cooling process, the special cross section and the rapid shaping effect of the fiber are endowed, the specific surface area and cohesion of the fiber are increased, finally, the fiber structure is further optimized through secondary stretching, the molecular chain orientation degree and the rolling degree are improved, the fiber has good elasticity and wear resistance, and the monohydroxy in the oiling process is further improved;
2. The invention adopts the hydrophobic fiber bundles to prepare the pile layer under a specific tufting process, ensures the firmness and wear resistance of the pile, combines different layers step by step, ensures that the layers of the composite carpet have different functions, wherein the hydrophobic pile layer realizes water resistance and stain resistance by virtue of the hydrophobic fiber bundles, the adhesive layer combines water-based polyurethane foaming emulsion with an organosilicon material to ensure the firm bonding of the pile and the base cloth and reduces the smell, the supporting layer and the reinforcing layer are compounded by adopting PET material and PEPAPE laminated film, the integral strength and the stability of the carpet are enhanced, and the finally obtained composite carpet is excellent in hydrolysis resistance, wear resistance, high-low temperature resistance, color fastness and the like, can keep structural integrity no matter facing water stain erosion, high-frequency treading, extreme temperature and illumination environment, and has stable performance, and shows the reliability and durability of far-reaching ultra-conventional carpets.
Drawings
FIG. 1 is a graph showing the gasoline resistance of the polymer hydrolysis-resistant composite carpet of example 1;
FIG. 2 is a front and back view of the high temperature resistance test of the polymer hydrolysis resistant composite carpet described in examples 1-3;
FIG. 3 is a front and back view of the polymer hydrolysis resistant composite carpet of examples 1-3 before and after the low temperature test;
fig. 4 is a graph showing the effect of the polymer hydrolysis-resistant composite carpet described in examples 1 to 3 before and after illumination.
Detailed Description
The invention is described in detail below with reference to examples:
The invention provides a macromolecule hydrolysis-resistant composite carpet, a preparation method and application thereof, which greatly improves the hydrolysis resistance of the carpet and improves the mechanical properties, weather resistance, corrosion resistance and the like of the composite carpet by preparing hydrophobic fiber bundles and an adhesive layer.
Example 1
The embodiment provides a high-molecular hydrolysis-resistant composite carpet, which comprises a bottom layer, a second supporting layer, a reinforcing layer, a first supporting layer, an adhesive layer, a base cloth layer and a hydrophobic pile layer from bottom to top, wherein the hydrophobic pile layer is formed by melting and spinning a polyamide 6 mixed polyester modified organic silicon resin and maleic anhydride grafted polyamide to prepare a hydrophobic fiber bundle, tufting the hydrophobic fiber bundle onto the base cloth layer through a tufting machine, continuously coating a water-based polyurethane foaming latex mixed polyester modified organic silicon resin and a maleic anhydride grafted polyolefin elastomer on the bottom of the base cloth layer to obtain the adhesive layer, and continuously and sequentially compounding other first supporting layer, the reinforcing layer, the second supporting layer and the bottom layer to obtain the high-molecular hydrolysis-resistant composite carpet;
the thickness of the polymer hydrolysis-resistant composite carpet is 10mm, the pile height is 4mm, the pile shape is cut pile, the pile cluster pulling-out force is 24N, and the pile cluster pulling-out force after soaking is 23N;
the heat-resistant dimensional stability of the polymer hydrolysis-resistant composite carpet is 0.51% in the warp direction and 0.58% in the weft direction;
The stability of the water immersion size of the polymer hydrolysis resistant composite carpet is 0.57% in the warp direction and 0.64% in the weft direction;
The polymer hydrolysis-resistant composite carpet has a water-soaking color fastness of 4.5 levels, a light color fastness of 4 levels, and a color fastness of 4 levels after washing resistance and gasoline testing;
the wear-resistant number of turns of the polymer hydrolysis-resistant composite carpet is 3000, the abrasion-resistant number of turns is not leaked, and the stripping force is 34N;
the polymer hydrolysis-resistant composite carpet has no cracks, layering, foaming, shrinkage, deformation and pungent smell after being placed for 24 hours at the temperature of-40 ℃ (low temperature resistance), being placed for 168 hours at the temperature of 90 ℃ (high temperature resistance) and being irradiated under illumination.
The embodiment also provides a preparation method of the polymer hydrolysis-resistant composite carpet, which comprises the following steps:
Step 1, adding polyamide 6, maleic anhydride grafted polyamide, polyester modified organic silicon resin and color master into a high-speed mixer at 800rpm, stirring and mixing for 2min to obtain a mixture, extruding and spinning the mixture through a screw extruder, wherein the processing temperature of the screw extruder is 220-250 ℃, the processing temperature of the screw extruder is divided into four temperature areas, the temperature of the first temperature area is 220 ℃, the temperature of the second temperature area is 240 ℃, the temperature of the third temperature area is 250 ℃, the temperature of the fourth temperature area is 240 ℃, the materials are melt-blended in the screw extruder and then are spun through a trilobal spinneret plate, the number of holes of the trilobal spinneret plate is 50, and the hydrophobic fiber yarn is obtained after air cooling at 15 ℃;
Step 2, oiling the hydrophobic fiber yarn, wherein the oiling type is monohydroxy silicone oil, the oiling rate is 0.6%, carrying out primary stretching on the oiled hydrophobic fiber yarn, wherein the primary stretching temperature is 80 ℃, the stretching multiplying power is 1.01, carrying out secondary stretching, the secondary stretching temperature is 170 ℃, the stretching multiplying power is 2.3, carrying out jet puffing on the stretched hydrophobic fiber yarn under the pressure of 170 ℃ and a nozzle pressure of 5bar, cooling by a cooling roller, wherein the temperature of the cooling roller is 25 ℃, the rotating speed is 30rpm, continuously knotting the hydrophobic fiber yarn in a spinning network device, and the knotting number of the hydrophobic fiber yarn is 25+/-1, wherein the gas pressure of the spinning network device is 4bar, and obtaining a hydrophobic fiber bundle after winding by a winding machine;
The total crimp degree of the hydrophobic fiber bundles is 15%, the fineness is 1500D, and the number of holes is 50;
Step 3, setting 120gsm of polyethylene terephthalate (PET) non-woven base fabric, tufting the hydrophobic fiber bundles onto the non-woven base fabric, wherein the tufting needle distance is 1/10, the weft knitting density is 39.37 needles/cm, the warp knitting density is 50 needles/cm, the needling depth is 5.5mm, and the needle frequency is 1000rpm, so as to obtain a hydrophobic pile layer and a base fabric layer;
Step 4, coating aqueous polyurethane foaming latex (the foaming ratio is 2.0 times), a maleic anhydride grafted polyolefin elastomer (maleic anhydride grafted POE) and polyester modified organic silicon resin at the mass ratio of 4:1:1 at 800rpm for 8min, and then coating the mixture on the bottom of the base cloth layer at the speed of 10m/min, and drying the mixture at 150 ℃ for 3min to obtain a 100gsm adhesive layer;
And 5, spraying 300gsm of polyethylene bonded polyethylene-polyamide-polyethylene film (PEPAPE) at the bottom of the bonding layer at the speed of 3m/min, spraying 300gsm of polyethylene bonded polyethylene terephthalate (PET) needled base felt, cooling to obtain 100gsm of first supporting layer and 300gsm of reinforcing layer, continuously spraying 300gsm of polyethylene bonded polyethylene-polyamide-polyethylene film (PEPAPE) at the bottom of the reinforcing layer at the speed of 230 ℃ and cooling to obtain 100gsm of second supporting layer and 200gsm of base layer, and finally obtaining the high-molecular hydrolysis-resistant composite carpet.
As shown in fig. 1, the polymer hydrolysis-resistant composite carpet in this example 1 was tested for gasoline resistance, and it can be seen that the polymer hydrolysis-resistant composite carpet in this example was free from discoloration and surface changes after being subjected to a corrosiveness test.
Example 2
The embodiment provides a high-molecular hydrolysis-resistant composite carpet, which comprises a bottom layer, a second supporting layer, a reinforcing layer, a first supporting layer, an adhesive layer, a base cloth layer and a hydrophobic pile layer from bottom to top, wherein the hydrophobic pile layer is formed by melting and spinning a polyamide 6 mixed polyester modified organic silicon resin and maleic anhydride grafted polyamide to prepare a hydrophobic fiber bundle, tufting the hydrophobic fiber bundle onto the base cloth layer through a tufting machine, continuously coating a water-based polyurethane foaming latex mixed polyester modified organic silicon resin and a maleic anhydride grafted polyolefin elastomer on the bottom of the base cloth layer to obtain the adhesive layer, and continuously and sequentially compounding other first supporting layer, the reinforcing layer, the second supporting layer and the bottom layer to obtain the high-molecular hydrolysis-resistant composite carpet;
the thickness of the polymer hydrolysis-resistant composite carpet is 12mm, the pile height is 3mm, the pile shape is cut pile, the pile cluster pulling-out force is 21N, and the pile cluster pulling-out force after soaking is 20N;
the heat-resistant dimensional stability of the polymer hydrolysis-resistant composite carpet is 0.72% in the warp direction and 0.76% in the weft direction;
The stability of the water immersion size of the polymer hydrolysis resistant composite carpet is 0.66% in the warp direction and 0.71% in the weft direction;
The polymer hydrolysis-resistant composite carpet has a water-soaking color fastness of 5 levels, a light color fastness of 4 levels and a color fastness of 5 levels after being tested by detergents and gasoline;
The wear-resistant number of turns of the polymer hydrolysis-resistant composite carpet is 3000, the abrasion-resistant number of turns is not leaked, and the stripping force is 28N;
The polymer hydrolysis-resistant composite carpet has no cracks, layering, foaming, shrinkage, deformation and pungent odor after being placed for 24 hours at the temperature of-40 ℃, 168 hours at the temperature of 90 ℃ and irradiated under illumination.
The embodiment also provides a preparation method of the polymer hydrolysis-resistant composite carpet, which comprises the following steps:
Step 1, adding polyamide 6, maleic anhydride grafted polyamide, polyester modified organic silicon resin and color master in a high-speed mixer with the mass ratio of 80:7:8:3, stirring and mixing for 7min to obtain a mixture, extruding and spinning the mixture through a screw extruder, wherein the processing temperature of the screw extruder is 230-260 ℃, the processing temperature of the screw extruder is divided into four temperature areas, the temperature of the first temperature area is 230 ℃, the temperature of the second temperature area is 250 ℃, the temperature of the third temperature area is 260 ℃, the temperature of the fourth temperature area is 240 ℃, the materials are melt-blended in the screw extruder and then are spun through a trilobal spinneret plate, the number of holes of the trilobal spinneret plate is 55, and the hydrophobic fiber yarn is obtained after air cooling at 20 ℃;
Step 2, oiling the hydrophobic fiber yarn, wherein the oiling type is monohydroxy silicone oil, the oiling rate is 0.8%, carrying out primary stretching on the oiled hydrophobic fiber yarn, wherein the primary stretching temperature is 85 ℃, the stretching multiplying power is 1.01, carrying out secondary stretching, the secondary stretching temperature is 190 ℃, the stretching multiplying power is 2.3, carrying out jet puffing on the stretched hydrophobic fiber yarn under the pressure of 170 ℃ and a nozzle pressure of 5bar, cooling by a cooling roller, wherein the temperature of the cooling roller is 25 ℃, the rotating speed is 30rpm, continuously knotting the hydrophobic fiber yarn in a spinning network device, and the knotting number of the hydrophobic fiber yarn is 26+/-1, wherein the gas pressure of the spinning network device is 4bar, and obtaining a hydrophobic fiber bundle after winding by a winding machine;
the total crimp degree of the hydrophobic fiber bundles is 16%, the fineness is 1900D, and the number of holes is 55;
step 3, setting 130gsm of polyethylene terephthalate (PET) non-woven base fabric, tufting the hydrophobic fiber bundles onto the non-woven base fabric, wherein the tufting needle distance is 1/10, the weft knitting density is 39.37 needles/cm, the warp knitting density is 55 needles/cm, the needle penetration depth is 5mm, and the needle frequency is 1000rpm, so as to obtain a hydrophobic pile layer and a base fabric layer;
Step 4, coating aqueous polyurethane foaming latex (the foaming ratio is 2.0 times), maleic anhydride grafted polyolefin elastomer and polyester modified organic silicon resin at a mass ratio of 4:1:2 at 800rpm for 8min, coating the mixture on the bottom of the base cloth layer at a speed of 15m/min, and drying at 190 ℃ for 2min to obtain a 130gsm adhesive layer;
And 5, spraying 200gsm of polyethylene bonded polyethylene-polyamide-polyethylene film (PEPAPE) at the bottom of the bonding layer at the speed of 3m/min, spraying 200gsm of polyethylene bonded polyethylene terephthalate (PET) needled base felt, cooling to obtain 200gsm of first supporting layer and 400gsm of reinforcing layer, continuously spraying 200gsm of polyethylene bonded polyethylene-polyamide-polyethylene film (PEPAPE) at the bottom of the reinforcing layer at the speed of 3m/min, spraying 200gsm of polyethylene bonded polyethylene terephthalate (PET) nonwoven base fabric at the speed of 230 ℃, cooling to obtain 200gsm of second supporting layer and 300gsm of base layer, and finally obtaining the high-molecular hydrolysis-resistant composite carpet.
Example 3
The embodiment provides a high-molecular hydrolysis-resistant composite carpet, which comprises a bottom layer, a second supporting layer, a reinforcing layer, a first supporting layer, an adhesive layer, a base cloth layer and a hydrophobic pile layer from bottom to top, wherein the hydrophobic pile layer is formed by melting and spinning a polyamide 6 mixed polyester modified organic silicon resin and maleic anhydride grafted polyamide to prepare a hydrophobic fiber bundle, tufting the hydrophobic fiber bundle onto the base cloth layer through a tufting machine, continuously coating a water-based polyurethane foaming latex mixed polyester modified organic silicon resin and a maleic anhydride grafted polyolefin elastomer on the bottom of the base cloth layer to obtain the adhesive layer, and continuously and sequentially compounding other first supporting layer, the reinforcing layer, the second supporting layer and the bottom layer to obtain the high-molecular hydrolysis-resistant composite carpet;
the thickness of the polymer hydrolysis-resistant composite carpet is 14mm, the pile height is 5mm, the pile shape is cut pile, the pile cluster pulling-out force is 25N, and the pile cluster pulling-out force after soaking is 25N;
The heat-resistant dimensional stability of the polymer hydrolysis-resistant composite carpet is 0.61% in the warp direction and 0.57% in the weft direction;
The stability of the water immersion size of the polymer hydrolysis resistant composite carpet is 0.69% in the warp direction and 0.62% in the weft direction;
The polymer hydrolysis-resistant composite carpet has a water-soaking color fastness of 4.5 levels, a light color fastness of 4 levels and a color fastness of 5 levels after being tested by detergents and gasoline;
the wear-resistant number of turns of the polymer hydrolysis-resistant composite carpet is 2900 turns, no bottom leakage occurs, and the stripping force is 29N;
The polymer hydrolysis-resistant composite carpet has no cracks, layering, foaming, shrinkage, deformation and pungent odor after being placed for 24 hours at the temperature of-40 ℃, 168 hours at the temperature of 90 ℃ and irradiated under illumination.
The embodiment also provides a preparation method of the polymer hydrolysis-resistant composite carpet, which comprises the following steps:
Step 1, adding polyamide 6, maleic anhydride grafted polyamide, polyester modified organic silicon resin and color master into a high-speed mixer at 600rpm, stirring and mixing for 4min to obtain a mixture, extruding and spinning the mixture through a screw extruder, wherein the processing temperature of the screw extruder is 220-250 ℃, the temperature of the first temperature zone is 220 ℃, the temperature of the second temperature zone is 240 ℃, the temperature of the third temperature zone is 250 ℃, the temperature of the fourth temperature zone is 240 ℃, the materials are melt-blended in the screw extruder and then are spun through a trilobal spinneret plate, the number of holes of the trilobal spinneret plate is 60, and the hydrophobic fiber yarn is obtained after air cooling at 25 ℃;
Step 2, oiling the hydrophobic fiber yarn, wherein the oiling type is monohydroxy silicone oil, the oiling rate is 0.7%, carrying out primary stretching on the oiled hydrophobic fiber yarn, wherein the primary stretching temperature is 90 ℃, the stretching multiplying power is 1.01, carrying out secondary stretching, the secondary stretching temperature is 180 ℃, the stretching multiplying power is 2.3, carrying out jet puffing on the stretched hydrophobic fiber yarn under 170 ℃ and 4bar pressure of a nozzle, cooling by a cooling roller, wherein the temperature of the cooling roller is 20 ℃, the rotating speed is 30rpm, continuously knotting the hydrophobic fiber yarn in a spinning network device, and the knotting number of the hydrophobic fiber yarn is 27+/-1, wherein the gas pressure of the spinning network device is 3bar, and obtaining a hydrophobic fiber bundle after winding by a winding machine;
the total crimp degree of the hydrophobic fiber bundles is 15%, the fineness is 1800D, and the number of holes is 60;
Step 3, setting 120gsm of polyethylene terephthalate (PET) non-woven base fabric, tufting the hydrophobic fiber bundles onto the non-woven base fabric, wherein the tufting needle distance is 1/10, the weft knitting density is 39.37 needles/cm, the warp knitting density is 60 needles/cm, the needle penetration depth is 6mm, and the needle frequency is 800rpm, so as to obtain a hydrophobic pile layer and a base fabric layer;
step 4, coating aqueous polyurethane foaming latex (the foaming ratio is 3.0 times), maleic anhydride grafted polyolefin elastomer and polyester modified organic silicon resin at a mass ratio of 4:1:1 at 700rpm for 9min, coating the mixture on the bottom of the base cloth layer at a speed of 9m/min, and drying the mixture at 130 ℃ for 4min to obtain a 50gsm adhesive layer;
And 5, spraying 500gsm of polyethylene bonded polyethylene-polyamide-polyethylene film (PEPAPE) at the bottom of the bonding layer at the speed of 4m/min, spraying 500gsm of polyethylene bonded polyethylene terephthalate (PET) needled base felt, cooling to obtain 300gsm of first supporting layer and 300gsm of reinforcing layer, continuously spraying 500gsm of polyethylene bonded polyethylene-polyamide-polyethylene film (PEPAPE) at the bottom of the reinforcing layer at the speed of 230 ℃ at the speed of 3m/min, spraying 500gsm of polyethylene bonded polyethylene terephthalate (PET) nonwoven base fabric, cooling to obtain 300gsm of second supporting layer and 200gsm of base layer, and finally obtaining the high-molecular hydrolysis-resistant composite carpet.
Fig. 2-4 are graphs showing the effects of the high temperature resistant, low temperature resistant, and light resistant carpet of the polymer hydrolysis resistant composite carpet of examples 1-3, wherein the surface of the carpet is not significantly changed after the carpet is tested.
Example 4
The embodiment provides a high-molecular hydrolysis-resistant composite carpet, which comprises a bottom layer, a second supporting layer, a reinforcing layer, a first supporting layer, an adhesive layer, a base cloth layer and a hydrophobic pile layer from bottom to top, wherein the hydrophobic pile layer is formed by melting and spinning a polyamide 6 mixed polyester modified organic silicon resin and maleic anhydride grafted polyamide to prepare a hydrophobic fiber bundle, tufting the hydrophobic fiber bundle onto the base cloth layer through a tufting machine, continuously coating a water-based polyurethane foaming latex mixed polyester modified organic silicon resin and a maleic anhydride grafted polyolefin elastomer on the bottom of the base cloth layer to obtain the adhesive layer, and continuously and sequentially compounding other first supporting layer, the reinforcing layer, the second supporting layer and the bottom layer to obtain the high-molecular hydrolysis-resistant composite carpet;
the thickness of the polymer hydrolysis-resistant composite carpet is 10mm, the pile height is 4mm, the pile shape is cut pile, the pile cluster pulling-out force is 22N, and the pile cluster pulling-out force after soaking is 20N;
The heat-resistant dimensional stability of the polymer hydrolysis-resistant composite carpet is 0.72% in the warp direction and 0.78% in the weft direction;
The stability of the water immersion size of the polymer hydrolysis resistant composite carpet is 0.76% in the warp direction and 0.72% in the weft direction;
The polymer hydrolysis-resistant composite carpet has a water-soaking color fastness of 5 levels, a light color fastness of 4 levels, and a color fastness of 4 levels after being tested by detergents and gasoline;
the wear-resistant number of turns of the polymer hydrolysis-resistant composite carpet is 2950, no bottom leakage occurs, and the stripping force is 33N;
The polymer hydrolysis-resistant composite carpet has no cracks, layering, foaming, shrinkage, deformation and pungent odor after being placed for 24 hours at the temperature of-40 ℃, 168 hours at the temperature of 90 ℃ and irradiated under illumination.
The embodiment also provides a preparation method of the polymer hydrolysis-resistant composite carpet, which comprises the following steps:
Step 1, adding polyamide 6, maleic anhydride grafted polyamide, polyester modified organic silicon resin and color master into a high-speed mixer at 800rpm, stirring and mixing for 2min to obtain a mixture, extruding and spinning the mixture through a screw extruder, wherein the processing temperature of the screw extruder is 220-250 ℃, the processing temperature of the screw extruder is divided into four temperature areas, the temperature of the first temperature area is 220 ℃, the temperature of the second temperature area is 240 ℃, the temperature of the third temperature area is 250 ℃, the temperature of the fourth temperature area is 240 ℃, the materials are melt-blended in the screw extruder and then are spun through a trilobal spinneret plate, the number of holes of the trilobal spinneret plate is 50, and the hydrophobic fiber yarn is obtained after air cooling at 15 ℃;
Step 2, oiling the hydrophobic fiber yarn, wherein the oiling type is monohydroxy silicone oil, the oiling rate is 0.6%, carrying out primary stretching on the oiled hydrophobic fiber yarn, wherein the primary stretching temperature is 80 ℃, the stretching multiplying power is 1.01, carrying out secondary stretching, the secondary stretching temperature is 170 ℃, the stretching multiplying power is 2.3, carrying out jet puffing on the stretched hydrophobic fiber yarn under the pressure of 200 ℃ and a nozzle pressure of 5bar, cooling by a cooling roller, wherein the temperature of the cooling roller is 25 ℃, the rotating speed is 40rpm, continuously knotting the hydrophobic fiber yarn in a spinning network device, and the knotting number of the hydrophobic fiber yarn is 25+/-1, wherein the gas pressure of the spinning network device is 4bar, and obtaining a hydrophobic fiber bundle after winding by a winding machine;
the total crimp degree of the hydrophobic fiber bundles is 18%, the fineness is 1500D, and the number of holes is 50;
step 3, setting 140gsm of polyethylene terephthalate (PET) non-woven base cloth, tufting the hydrophobic fiber bundles onto the non-woven base cloth, wherein the tufting needle distance is 5/64, the weft knitting density is 50.39 needles/cm, the warp knitting density is 50 needles/cm, the needle penetration depth is 5.5mm, and the needle frequency is 1000rpm, so as to obtain a hydrophobic pile layer and a base cloth layer;
Step 4, coating aqueous polyurethane foaming latex (the foaming ratio is 2.0 times), maleic anhydride grafted polyolefin elastomer and polyester modified organic silicon resin at a mass ratio of 4:1:1 at 600rpm for 10min, coating the mixture on the bottom of the base cloth layer at a speed of 10m/min, and drying at 140 ℃ for 4min to obtain a 100gsm adhesive layer;
And 5, spraying 400gsm of polyethylene bonded polyethylene-polyamide-polyethylene film (PEPAPE) at the bottom of the bonding layer at the speed of 3m/min, spraying 400gsm of polyethylene bonded polyethylene terephthalate (PET) needled base felt, cooling to obtain 100gsm of first support layer and 400gsm of reinforcing layer, continuously spraying 400gsm of polyethylene bonded polyethylene-polyamide-polyethylene film (PEPAPE) at the bottom of the reinforcing layer at the speed of 230 ℃ at the speed of 3m/min, cooling to obtain 200gsm of second support layer and 300gsm of base layer, and finally obtaining the high-molecular hydrolysis-resistant composite carpet.
Comparative example 1
The composite carpet comprises a bottom layer, a second supporting layer, a reinforcing layer, a first supporting layer, an adhesive layer, a base cloth layer and a pile layer from bottom to top, wherein the pile layer is formed by melting polyamide 6 and a color masterbatch, spinning to obtain fiber bundles, tufting the fiber bundles onto the base cloth layer through a tufting machine, continuously coating aqueous polyurethane foaming latex mixed polyester modified organic silicon resin and maleic anhydride grafted polyolefin elastomer on the bottom of the base cloth layer to obtain the adhesive layer, and continuously and sequentially compounding other first supporting layer, the reinforcing layer, the second supporting layer and the bottom layer to obtain the composite carpet;
the thickness of the composite carpet is 10mm, the pile height is 4mm, the pile shape is cut pile, the pile cluster pulling-out force is 18N, and the pile cluster pulling-out force after soaking is 16N;
The heat-resistant dimensional stability of the composite carpet is 1.01 percent in the warp direction and 1.00 percent in the weft direction;
the dimensional stability of the composite carpet in water immersion is 1.23% in the warp direction and 1.21% in the weft direction;
The composite carpet has a water-soaking color fastness of 3.5, a light color fastness of 3.5, and a color fastness of 4 after being tested by a detergent and gasoline;
The abrasion-resistant circle number of the composite carpet is 2900, no bottom leakage occurs, and the stripping force is 22N.
The comparative example also provides a method for preparing the composite carpet, comprising the following steps:
Step 1, adding polyamide 6 and a color masterbatch with the mass ratio of 80:2 into a high-speed mixer at 800rpm, stirring and mixing for 2min to obtain a mixture, extruding and spinning the mixture through a screw extruder, wherein the processing temperature of the screw extruder is 220-250 ℃ and is divided into four temperature areas, the temperature of the first temperature area is 220 ℃, the temperature of the second temperature area is 240 ℃, the temperature of the third temperature area is 250 ℃, the temperature of the fourth temperature area is 240 ℃, and spinning the mixture through a trilobal spinneret plate after melt blending the materials in the screw extruder, wherein the number of holes of the trilobal spinneret plate is 50, and rapidly cooling the materials under 15 ℃ to obtain fiber filaments;
Step 2, oiling the fiber yarn, wherein the oiling type is monohydroxy silicone oil, the oiling rate is 0.6%, carrying out primary stretching on the fiber yarn after oiling, wherein the primary stretching temperature is 80 ℃, the stretching multiplying power is 1.01, carrying out secondary stretching, the secondary stretching temperature is 170 ℃, the stretching multiplying power is 2.3, carrying out jet puffing on the stretched fiber yarn under the pressure of 170 ℃ and a nozzle pressure of 5bar, cooling by a cooling roller, wherein the temperature of the cooling roller is 25 ℃, the rotating speed is 30rpm, continuously knotting the fiber yarn in a spinning network device, the knotting number is 25+/-1, and the gas pressure of the spinning network device is 4bar, and obtaining a fiber bundle after winding by a winding machine;
The total crimp degree of the fiber bundles is 15%, the fineness is 1500D, and the number of holes is 50;
Step 3, setting 120gsm of polyethylene terephthalate (PET) non-woven base cloth, tufting the fiber bundles onto the non-woven base cloth, wherein the tufting needle distance is 1/10, the weft knitting density is 39.37 needles/cm, the warp knitting density is 50 needles/cm, the needle penetration depth is 5.5mm, and the needle frequency is 1000rpm, so as to obtain a hydrophobic pile layer and a base cloth layer;
Step 4, coating aqueous polyurethane foaming latex (the foaming ratio is 2.0 times), a maleic anhydride grafted polyolefin elastomer (maleic anhydride grafted POE) and polyester modified organic silicon resin at the mass ratio of 4:1:1 at 800rpm for 8min, and then coating the mixture on the bottom of the base cloth layer at the speed of 10m/min, and drying the mixture at 150 ℃ for 3min to obtain a 100gsm adhesive layer;
And 5, spraying 300gsm of polyethylene bonded polyethylene-polyamide-polyethylene film (PEPAPE) at the bottom of the bonding layer at the speed of 3m/min, spraying 300gsm of polyethylene bonded polyethylene terephthalate (PET) needled base felt, cooling to obtain 200gsm of first supporting layer and 300gsm of reinforcing layer, continuously spraying 300gsm of polyethylene bonded polyethylene-polyamide-polyethylene film (PEPAPE) at the bottom of the reinforcing layer at the speed of 230 ℃ and cooling to obtain 200gsm of second supporting layer and 200gsm of base layer, and finally obtaining the high-molecular hydrolysis-resistant composite carpet.
Comparative example 2
The composite carpet comprises a bottom layer, a second supporting layer, a reinforcing layer, a first supporting layer, an adhesive layer, a base cloth layer and a hydrophobic pile layer from bottom to top, wherein the hydrophobic pile layer is formed by melting and spinning a polyamide 6 mixed polyester modified organic silicon resin and maleic anhydride grafted polyamide to prepare a hydrophobic fiber bundle, tufting the hydrophobic fiber bundle onto the base cloth layer through a tufting machine, coating a water-based polyurethane foaming latex mixed polyester modified organic silicon resin and a maleic anhydride grafted polyolefin elastomer on the bottom of the base cloth layer to obtain the adhesive layer, and continuously and sequentially compounding other first supporting layer, the reinforcing layer, the second supporting layer and the bottom layer to obtain the composite carpet;
the thickness of the composite carpet is 10mm, the pile height is 4mm, the pile shape is cut pile, the pile cluster pulling-out force is 19N, and the pile cluster pulling-out force after soaking is 15N;
the heat-resistant dimensional stability of the composite carpet is 0.95% in the warp direction and 0.89% in the weft direction;
The water immersion dimensional stability of the composite carpet is 0.80 percent in the warp direction and 0.85 percent in the weft direction;
The composite carpet has a water-soaking color fastness of 4 grades, a light color fastness of 4 grades, and a color fastness of 4 grades after washing resistance and gasoline testing;
the wear-resistant turns of the composite carpet are 3000 turns, the composite carpet is free from bottom leakage, and the stripping force is 23N.
The comparative example also provides a method for preparing the composite carpet, comprising the following steps:
Step 1, adding polyamide 6, maleic anhydride grafted polyamide, polyester modified organic silicon resin and color master into a high-speed mixer at 800rpm, stirring and mixing for 2min to obtain a mixture, extruding and spinning the mixture through a screw extruder, wherein the processing temperature of the screw extruder is 220-250 ℃, the processing temperature of the screw extruder is divided into four temperature areas, the temperature of the first temperature area is 220 ℃, the temperature of the second temperature area is 240 ℃, the temperature of the third temperature area is 250 ℃, the temperature of the fourth temperature area is 240 ℃, the materials are melt-blended in the screw extruder and then are spun through a trilobal spinneret plate, the number of holes of the trilobal spinneret plate is 50, and the hydrophobic fiber yarn is obtained after air cooling at 15 ℃;
Step 2, oiling the hydrophobic fiber yarn, wherein the oiling rate is 0.6% of a conventional spinning oiling agent, carrying out primary stretching on the oiled hydrophobic fiber yarn, wherein the primary stretching temperature is 80 ℃, the stretching multiplying power is 1.01, carrying out secondary stretching, the secondary stretching temperature is 170 ℃, the stretching multiplying power is 2.3, carrying out jet puffing on the stretched hydrophobic fiber yarn under the pressure of 170 ℃ and a nozzle pressure of 5bar, cooling by a cooling roller, wherein the temperature of the cooling roller is 25 ℃, the rotating speed is 30rpm, continuously carrying out knotting on the hydrophobic fiber yarn in a spinning network device, and carrying out winding on the spinning network device under the gas pressure of 4bar to obtain a hydrophobic fiber bundle;
The total crimp degree of the hydrophobic fiber bundles is 15%, the fineness is 1500D, and the number of holes is 50;
Step 3, setting 120gsm of polyethylene terephthalate (PET) non-woven base fabric, tufting the hydrophobic fiber bundles onto the non-woven base fabric, wherein the tufting needle distance is 1/10, the weft knitting density is 39.37 needles/cm, the warp knitting density is 50 needles/cm, the needling depth is 5.5mm, and the needle frequency is 1000rpm, so as to obtain a hydrophobic pile layer and a base fabric layer;
Step 4, coating aqueous polyurethane foaming latex (the foaming ratio is 2.0 times), a maleic anhydride grafted polyolefin elastomer (maleic anhydride grafted POE) and polyester modified organic silicon resin at the mass ratio of 4:1:1 at 800rpm for 8min, and then coating the mixture on the bottom of the base cloth layer at the speed of 10m/min, and drying the mixture at 150 ℃ for 3min to obtain a 100gsm adhesive layer;
And 5, spraying 300gsm of polyethylene bonded polyethylene-polyamide-polyethylene film (PEPAPE) at the bottom of the bonding layer at the speed of 3m/min, spraying 300gsm of polyethylene bonded polyethylene terephthalate (PET) needled base felt, cooling to obtain 200gsm of first supporting layer and 300gsm of reinforcing layer, continuously spraying 300gsm of polyethylene bonded polyethylene-polyamide-polyethylene film (PEPAPE) at the bottom of the reinforcing layer at the speed of 230 ℃ and cooling to obtain 200gsm of second supporting layer and 200gsm of base layer, and finally obtaining the high-molecular hydrolysis-resistant composite carpet.
Comparative example 3
The composite carpet comprises a bottom layer, a second supporting layer, a reinforcing layer, a first supporting layer, an adhesive layer, a base cloth layer and a hydrophobic pile layer from bottom to top, wherein the hydrophobic pile layer is formed by melting and spinning polyamide 6 mixed polyester modified organic silicon resin and maleic anhydride grafted polyamide to prepare a hydrophobic fiber bundle, tufting the hydrophobic fiber bundle onto the base cloth layer through a tufting machine, continuously coating aqueous polyurethane foaming emulsion on the base cloth layer to obtain the adhesive layer, and continuously and sequentially compounding other first supporting layer, the reinforcing layer, the second supporting layer and the bottom layer to obtain the composite carpet;
The thickness of the composite carpet is 10mm, the pile height is 4mm, the pile shape is cut pile, the pile cluster pulling-out force is 17N, and the pile cluster pulling-out force after soaking is 14N;
The heat-resistant dimensional stability of the composite carpet is 0.67% in the warp direction and 0.69% in the weft direction;
The dimensional stability of the composite carpet in water immersion is 0.71% in the warp direction and 0.73% in the weft direction;
The composite carpet has a water-soaking color fastness of 3.5, a light color fastness of 4, and a color fastness of 4 after being tested by detergent and gasoline;
The wear-resistant turns of the composite carpet are 2850 turns, the composite carpet does not leak from the bottom, and the stripping force is 25N;
The composite carpet has no cracks, delamination, foaming, shrinkage, deformation and pungent odor after being placed for 24 hours at the temperature of-40 ℃ (low temperature resistance), being placed for 168 hours at the temperature of 90 ℃ (high temperature resistance) and being irradiated under illumination.
The comparative example also provides a method for preparing the composite carpet, comprising the following steps:
Step 1, adding polyamide 6, maleic anhydride grafted polyamide, polyester modified organic silicon resin and color master into a high-speed mixer at 800rpm, stirring and mixing for 2min to obtain a mixture, extruding and spinning the mixture through a screw extruder, wherein the processing temperature of the screw extruder is 220-250 ℃, the processing temperature of the screw extruder is divided into four temperature areas, the temperature of the first temperature area is 220 ℃, the temperature of the second temperature area is 240 ℃, the temperature of the third temperature area is 250 ℃, the temperature of the fourth temperature area is 240 ℃, the materials are melt-blended in the screw extruder and then are spun through a trilobal spinneret plate, the number of holes of the trilobal spinneret plate is 50, and the hydrophobic fiber yarn is obtained after air cooling at 15 ℃;
Step 2, oiling the hydrophobic fiber yarn, wherein the oiling type is monohydroxy silicone oil, the oiling rate is 0.6%, carrying out primary stretching on the oiled hydrophobic fiber yarn, wherein the primary stretching temperature is 80 ℃, the stretching multiplying power is 1.01, carrying out secondary stretching, the secondary stretching temperature is 170 ℃, the stretching multiplying power is 2.3, carrying out jet puffing on the stretched hydrophobic fiber yarn under the pressure of 170 ℃ and a nozzle pressure of 5bar, cooling by a cooling roller, wherein the temperature of the cooling roller is 25 ℃, the rotating speed is 30rpm, continuously knotting the hydrophobic fiber yarn in a spinning network device, and the knotting number of the hydrophobic fiber yarn is 25+/-1, wherein the gas pressure of the spinning network device is 4bar, and obtaining a hydrophobic fiber bundle after winding by a winding machine;
The total crimp degree of the hydrophobic fiber bundles is 15%, the fineness is 1500D, and the number of holes is 50;
Step 3, setting 120gsm of polyethylene terephthalate (PET) non-woven base fabric, tufting the hydrophobic fiber bundles onto the non-woven base fabric, wherein the tufting needle distance is 1/10, the weft knitting density is 39.37 needles/cm, the warp knitting density is 50 needles/cm, the needling depth is 5.5mm, and the needle frequency is 1000rpm, so as to obtain a hydrophobic pile layer and a base fabric layer;
step 4, coating aqueous polyurethane foaming latex (the foaming ratio is 2.0 times) on the bottom of the base cloth layer at the speed of 10m/min, and drying at 150 ℃ for 3min to obtain a 100gsm adhesive layer;
And 5, spraying 300gsm of polyethylene bonded polyethylene-polyamide-polyethylene film (PEPAPE) at the bottom of the bonding layer at the speed of 3m/min, spraying 300gsm of polyethylene bonded polyethylene terephthalate (PET) needled base felt, cooling to obtain 200gsm of first supporting layer and 300gsm of reinforcing layer, continuously spraying 300gsm of polyethylene bonded polyethylene-polyamide-polyethylene film (PEPAPE) at the bottom of the reinforcing layer at the speed of 230 ℃ and cooling to obtain 200gsm of second supporting layer and 200gsm of base layer, and finally obtaining the high-molecular hydrolysis-resistant composite carpet.
Comparative example 4
The composite carpet comprises a bottom layer, a second supporting layer, a reinforcing layer, a first supporting layer, an adhesive layer, a base cloth layer and a hydrophobic pile layer from bottom to top, wherein the hydrophobic pile layer is formed by melting and spinning a polyamide 6 mixed polyester modified organic silicon resin and maleic anhydride grafted polyamide to prepare a hydrophobic fiber bundle, tufting the hydrophobic fiber bundle onto the base cloth layer through a tufting machine, continuously coating a water-based polyurethane foaming latex mixed polyester modified organic silicon resin and a maleic anhydride grafted polyolefin elastomer on the bottom of the base cloth layer to obtain the adhesive layer, and continuously and sequentially compounding other first supporting layer, the reinforcing layer, the second supporting layer and the bottom layer to obtain the composite carpet;
The thickness of the composite carpet is 10mm, the pile height is 4mm, the pile shape is cut pile, the pile cluster pulling-out force is 17N, and the pile cluster pulling-out force after soaking is 15N;
the heat-resistant dimensional stability of the composite carpet is 0.55% in the warp direction and 0.58% in the weft direction;
The dimensional stability of the composite carpet in water immersion is 0.67% in the warp direction and 0.64% in the weft direction;
The composite carpet has a water-soaking color fastness of 4 grades, a light color fastness of 4 grades, and a color fastness of 4 grades after washing resistance and gasoline testing;
The abrasion-resistant turns of the composite carpet are 2500 turns, no bottom leakage occurs, and the stripping force is 19N;
The composite carpet has no cracks, delamination, foaming, shrinkage, deformation and pungent odor after being placed for 24 hours at the temperature of-40 ℃ (low temperature resistance), being placed for 168 hours at the temperature of 90 ℃ (high temperature resistance) and being irradiated under illumination.
The comparative example also provides a method for preparing the composite carpet, comprising the following steps:
step 1, adding polyamide 6, maleic anhydride grafted polyamide, polyester modified organic silicon resin and color master into a high-speed mixer at 800rpm, stirring and mixing for 2min to obtain a mixture, extruding and spinning the mixture through a screw extruder, wherein the processing temperature of the screw extruder is 220-250 ℃, the processing temperature of the screw extruder is divided into four temperature areas, the temperature of the first temperature area is 220 ℃, the temperature of the second temperature area is 240 ℃, the temperature of the third temperature area is 250 ℃, the temperature of the fourth temperature area is 240 ℃, the materials are melt-blended in the screw extruder and then are spun through a trilobal spinneret plate, the number of holes of the trilobal spinneret plate is 50, and the hydrophobic fiber yarn is obtained after air cooling at 15 ℃ rapidly;
Step 2, oiling the hydrophobic fiber yarn, wherein the oiling type is monohydroxy silicone oil, the oiling rate is 0.6%, carrying out primary stretching on the oiled hydrophobic fiber yarn, wherein the primary stretching temperature is 80 ℃, the stretching multiplying power is 1.01, carrying out secondary stretching, the secondary stretching temperature is 170 ℃, the stretching multiplying power is 2.3, carrying out jet puffing on the stretched hydrophobic fiber yarn under the pressure of 170 ℃ and a nozzle pressure of 5bar, cooling by a cooling roller, wherein the temperature of the cooling roller is 25 ℃, the rotating speed is 30rpm, continuously knotting the hydrophobic fiber yarn in a spinning network device, and the knotting number of the hydrophobic fiber yarn is 25+/-1, wherein the gas pressure of the spinning network device is 4bar, and obtaining a hydrophobic fiber bundle after winding by a winding machine;
The total crimp degree of the hydrophobic fiber bundles is 15%, the fineness is 1500D, and the number of holes is 50;
Step 3, setting 120gsm of polyethylene terephthalate (PET) non-woven base fabric, tufting the hydrophobic fiber bundles onto the non-woven base fabric, wherein the tufting needle distance is 1/10, the weft knitting density is 39.37 needles/cm, the warp knitting density is 50 needles/cm, the needling depth is 5.5mm, and the needle frequency is 1000rpm, so as to obtain a hydrophobic pile layer and a base fabric layer;
Step 4, coating aqueous polyurethane foaming latex (the foaming ratio is 2.0 times), a maleic anhydride grafted polyolefin elastomer (maleic anhydride grafted POE) and polyester modified organic silicon resin at the mass ratio of 4:1:1 at 800rpm for 8min, and then coating the mixture on the bottom of the base cloth layer at the speed of 10m/min, and drying the mixture at 150 ℃ for 3min to obtain a 100gsm adhesive layer;
And 5, spraying 300gsm of polyethylene bonded polyethylene-polyamide-polyethylene film (PEPAPE) at the bottom of the bonding layer at the speed of 3m/min, spraying 300gsm of polyethylene bonded polyethylene terephthalate (PET) needled base felt, cooling to obtain 200gsm of first supporting layer and 300gsm of reinforcing layer, continuously spraying 300gsm of polyethylene bonded polyethylene-polyamide-polyethylene film (PEPAPE) at the bottom of the reinforcing layer at the speed of 230 ℃ and cooling to obtain 200gsm of second supporting layer and 200gsm of base layer, and finally obtaining the high-molecular hydrolysis-resistant composite carpet.
The type of the polyester modified organic silicon resin is not limited, and the existing polyester modified organic silicon resin can be used;
The conventional spinning oil is a lipid fiber oil, and comprises the components of fatty glyceride, potassium alkyl phosphate and polyethylene glycol.
Table 1 shows the performance of the composite carpets of the present example and comparative example
As is clear from the table, the composite carpet in this example has good stability, high color fastness and excellent hydrolysis resistance, and also maintains high mechanical properties and abrasion resistance, while the comparative example 1 does not use the silicone to modify the polyamide 6, so that the pile layer has poor hydrophobicity, and affects the stability, color fastness and hydrolysis resistance of the composite carpet at the same time, the comparative example 2 does not use the monohydroxy silicone oil, so that the hydrolysis resistance of the composite carpet is reduced, the stability is poor, the adhesive layer in the comparative example 3 is only aqueous polyurethane foam latex, the water contact angle of the adhesive layer is greatly reduced, the quality ratio of the compatilizer, the silicone material and the polyamide 6 is improved in the comparative example 4, the fluidity of the polyamide 6 is affected by the mass increase of the silicone material, the fluidity is affected by the spinning process, and the performance of the fiber bundle is also reduced, and the mechanical properties and the hydrolysis resistance of the composite carpet are also reduced.
The test standard of the heat-resistant dimensional stability is Q/JQ 5106-2014, wherein the test condition is that the polymer hydrolysis-resistant composite carpet with 300mm is prepared, the warp and weft dimensions L 0 and L 1 of the polymer hydrolysis-resistant composite carpet are tested, the polymer hydrolysis-resistant composite carpet is placed in a high-temperature box with 50 ℃ for 8 hours, then is taken out and cooled to room temperature, and the warp and weft dimensions L 0 'and L 1' of the polymer hydrolysis-resistant composite carpet are tested again, wherein the warp stability= (L 0-L0'）/L0 is 100% and the weft stability= (L 1-L1'）/L1 is 100% respectively);
preparing 300mm of the polymer hydrolysis-resistant composite carpet, testing the warp and weft dimensions L 2 and L 3 of the polymer hydrolysis-resistant composite carpet, putting the polymer hydrolysis-resistant composite carpet in normal-temperature water for 1h, taking out the composite carpet, draining, and testing the warp and weft dimensions L 2 'and L 3' again, wherein the warp stability= (L 2-L2'）/L2 is 100% and the weft stability= (L 3-L3'）/L3 is 100%);
The test standard of the water-immersion color fastness of the high polymer hydrolysis-resistant composite carpet is Q/JQ 5106-2014.5.9, wherein the test condition is that the high polymer hydrolysis-resistant composite carpet is placed under the conditions of 20 ℃ and 60% RH for 24 hours, a piece of filter paper soaked with deionized water is placed on the high polymer hydrolysis-resistant composite carpet, and then the filter paper is clamped between glass sheets, and after a load of 5kg is given for 1 hour, the degree of coloration of the filter paper is compared according to GB250 gray cards;
The conditions of the illumination color fastness and the illumination test of the high polymer hydrolysis resistant composite carpet are irradiance of 1.20W/m 2 @420nm, black standard temperature of 100 ℃, in-box temperature of 65 ℃, relative humidity of 20% RH, test time of 195h and total irradiation quantity of 840KJ/m 2;
The color fastness grade test standard of the polymer hydrolysis-resistant composite carpet after the test of the detergent and the gasoline is QCT 216-2019.10, and the test condition is that the color fastness is compared after the polymer hydrolysis-resistant composite carpet is respectively soaked with neutral detergent with the diameter of 5cm and 120# solvent gasoline, and then dried or wiped at normal temperature until all the neutral detergent and the 120# solvent gasoline volatilize;
wherein a rating in color fastness and degree of coloration from 1 to 5,1 representing the worst color fastness, 5 representing the best ;
the conditions of the wear-resistant circle number test of the polymer hydrolysis-resistant composite carpet are that the speed is 70rpm, the load is 1000g, and the grinding wheel is H-18.
The number of the holes of the hydrophobic fiber bundles corresponds to the number of the holes of the spinneret plate, and the number of the holes of the hydrophobic fiber bundles is the number of fiber filaments in the fiber bundles.
According to the above, the polymer hydrolysis-resistant composite carpet has the advantages of wide application range, low cost and extremely high market prospect.
The above description is only of the preferred embodiment of the present invention, and is not intended to limit the present invention in any other way, but is intended to cover any modifications or equivalent variations according to the technical spirit of the present invention, which fall within the scope of the present invention as defined by the appended claims.
Claims (8)
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| CN1067459A (en) * | 1991-04-09 | 1992-12-30 | 北德纤维工厂有限公司 | tufted carpet |
| CN106113675A (en) * | 2016-06-21 | 2016-11-16 | 滨州东方地毯有限公司 | A kind of preparation method of tufted carpet without latex |
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| DE69418586T2 (en) * | 1994-01-07 | 1999-11-25 | E.I. Du Pont De Nemours And Co., Wilmington | Process for the production of a carpet with a liquid-impermeable backing and this carpet |
| CN108943889B (en) * | 2018-07-13 | 2021-06-29 | 金华洁灵家居用品有限公司 | High-brightness fluffy soft tufted carpet without falling down and manufacturing process thereof |
| CN112659687A (en) * | 2020-12-30 | 2021-04-16 | 昆山怡家居纺织有限公司 | Tufted chemical fiber carpet capable of being completely recycled and preparation method thereof |
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN1067459A (en) * | 1991-04-09 | 1992-12-30 | 北德纤维工厂有限公司 | tufted carpet |
| CN106113675A (en) * | 2016-06-21 | 2016-11-16 | 滨州东方地毯有限公司 | A kind of preparation method of tufted carpet without latex |
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