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CN115503296A - 一种耐磨聚氨酯行李箱地毯及其制备方法 - Google Patents

一种耐磨聚氨酯行李箱地毯及其制备方法 Download PDF

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Publication number
CN115503296A
CN115503296A CN202211353868.0A CN202211353868A CN115503296A CN 115503296 A CN115503296 A CN 115503296A CN 202211353868 A CN202211353868 A CN 202211353868A CN 115503296 A CN115503296 A CN 115503296A
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CN
China
Prior art keywords
carpet
acrylate
woven fabric
needled
pretreated
Prior art date
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Pending
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CN202211353868.0A
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English (en)
Inventor
刘希浪
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Changshu New Changtai Automobile Interior Technology Co ltd
Original Assignee
Changshu New Changtai Automobile Interior Technology Co ltd
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Priority to CN202211353868.0A priority Critical patent/CN115503296A/zh
Publication of CN115503296A publication Critical patent/CN115503296A/zh
Pending legal-status Critical Current

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Textile Engineering (AREA)
  • Health & Medical Sciences (AREA)
  • Medicinal Chemistry (AREA)
  • Polymers & Plastics (AREA)
  • Organic Chemistry (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Biochemistry (AREA)
  • General Chemical & Material Sciences (AREA)
  • Microbiology (AREA)
  • Transportation (AREA)
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Abstract

本发明公开了一种耐磨聚氨酯行李箱地毯及其制备方法，方案设计为多层复合地毯，其中地毯最上层为针刺面毯，该层作为装饰层，实际加工时可根据需要选择针刺面毯的材质，也可根据需要将针刺面毯替换为簇绒面毯；针刺面毯下方为聚乙烯胶板，聚乙烯胶板作为骨架层，能够使地毯保持挺括，不易变形，而且聚乙烯胶板的设计也能够保证地毯的力学性能；聚乙烯胶板下方设计了无纺布，无纺布作为间隔层，无纺布另一侧发泡形成聚氨酯发泡层，聚氨酯发泡层作为隔音层，能够保证地毯的隔音效果；最底层为聚乙烯保护膜，聚乙烯保护膜具有较优异的强度和耐磨性能，能够对聚氨酯发泡层进行保护。

Description

一种耐磨聚氨酯行李箱地毯及其制备方法
技术领域
本发明涉及地毯技术领域，具体为一种耐磨聚氨酯行李箱地毯及其制备方法。
背景技术
汽车行李箱地毯是汽车内饰的重要组成部分，现如今消费者对行李箱地毯的性能要求越来越高，不仅希望行李箱地毯能够增加汽车的豪华感和舒适感，而且还要求行李箱地毯具有优异的阻燃、隔音、防滑、耐用等性能，对地毯的抗菌性能也有一定的要求，而现如今市面上，行李箱地毯的性能无法满足消费者的需求。
基于该情况，本申请公开了一种耐磨聚氨酯行李箱地毯及其制备方法，以制备一种具有优异阻燃、抗菌性能的行李箱地毯。
发明内容
本发明的目的在于提供一种耐磨聚氨酯行李箱地毯及其制备方法，以解决上述背景技术中提出的问题。
为了解决上述技术问题，本发明提供如下技术方案：
一种耐磨聚氨酯行李箱地毯的制备方法，包括以下步骤：
(1)取针刺面毯、无纺布和保护膜，分别置于阻燃浸渍液中浸渍1～2h，取出后真空干燥，分别得到预处理针刺面毯、预处理无纺布和预处理保护膜；所述阻燃浸渍液为含有巯基的丙烯酸酯共聚乳液；
取预处理针刺面毯、聚乙烯胶板和预处理无纺布，以自上而下依次为预处理针刺面毯、聚乙烯胶板、预处理无纺布的顺序叠放，复合，形成地毯片；
(2)取聚酯多元醇、聚醚多元醇、扩链剂、发泡剂、三乙醇胺和泡沫稳定剂，30～40℃下混合均匀，得到A料；取二苯基甲烷二异氰酸酯、甲苯二异氰酸酯混合，得到B料；
将A料、B料混合，搅拌均匀，形成发泡料；将地毯片吸附至发泡模具中，并注入发泡料发泡，脱模，在地毯片的无纺布一侧发泡形成聚氨酯发泡层，再在聚氨酯发泡层表面复合预处理保护膜，形成地毯基体；
(3)取3-烯丙基-5,5-二甲基海因、乙烯基封端的聚二甲基硅氧烷和丙酮混合，加入安息香双甲醚，避光搅拌均匀，得到抗菌浸渍液；
将地毯基体转移至抗菌浸渍液中浸渍，紫外照射10～15min，取出，依次采用乙醇、去离子水洗涤，真空干燥，得到成品。
较优化的方案，步骤(2)中，各组分含量为：以质量计，聚酯多元醇10～20份、聚醚多元醇70～80份、二苯基甲烷二异氰酸酯20～30份、甲苯二异氰酸酯20～30份、扩链剂5～10份、发泡剂3～4份、三乙醇胺0.5～1份、泡沫稳定剂4～6份。
较优化的方案，所述扩链剂为1,4-丁二醇、丙三醇、丙二醇中的任意一种；所述发泡剂为水；所述泡沫稳定剂为羟基硅油。
较优化的方案，所述无纺布为PET无纺布，克重为80～100g/m2，厚度为1～2mm；所述针刺面毯的克重为400～600g/m2，厚度为8～10mm；所述聚氨酯发泡层的密度为40～50kg/m3，厚度为30～40mm；所述聚乙烯胶板的密度为3～4kg/m3，厚度为2～3mm；所述保护膜为聚乙烯膜。
较优化的方案，步骤(1)中，所述阻燃浸渍液的制备方法为：
S1：取3-巯基丙酸、季戊四醇和对甲苯磺酸，混合均匀，加热至85～95℃，反应5～6h，反应结束后收集产物，去离子水洗涤，减压蒸馏除水，得到季戊四醇酯；
S2：取季戊四醇酯、丙烯酸羟乙酯、氢氧化钠、六氯环三磷腈混合，加入四氢呋喃，油浴升温至90～100℃，回流搅拌反应8～12h，反应后静置冷却，抽滤收集产物，依次采用乙醇、去离子水洗涤，真空干燥，得到磷腈阻燃单体；
S3：取丙烯酸酯单体、磷腈阻燃单体、十二烷基硫酸钠和去离子水，剪切乳化20～30min，加热升温至80～90℃，加入过硫酸钾，反应2～3h，再加入氧化石墨烯，搅拌反应30-40min，得到阻燃浸渍液；所述丙烯酸酯单体包括丙烯酸甲酯、丙烯酸丁酯、甲基丙烯酸三氟乙酯和丙烯酸羟乙酯。
较优化的方案，步骤S3中，所述丙烯酸甲酯、丙烯酸丁酯、甲基丙烯酸三氟乙酯、丙烯酸羟乙酯的质量比为6：6：3：2；所述丙烯酸酯单体、磷腈阻燃单体、去离子水的质量比为6：3：7；所述十二烷基硫酸钠的用量为丙烯酸酯单体、磷腈阻燃单体总量的3～5wt％；所述过硫酸钾的用量为丙烯酸酯单体、磷腈阻燃单体总量的2～3wt％。
较优化的方案，步骤S1中，所述3-巯基丙酸与季戊四醇的摩尔比为1：(2～3)；步骤S2中，所述季戊四醇酯、六氯环三磷腈、丙烯酸羟乙酯的摩尔比为1：2：(6～7)。
较优化的方案，步骤(3)中，所述3-烯丙基-5,5-二甲基海因、乙烯基封端的聚二甲基硅氧烷的质量比为3：2；所述安息香双甲醚的用量为3-烯丙基-5,5-二甲基海因的2～3wt％。
较优化的方案，根据以上任一项所述的一种耐磨聚氨酯行李箱地毯的制备方法制备的行李箱地毯。
与现有技术相比，本发明所达到的有益效果是：
本发明公开了一种耐磨聚氨酯行李箱地毯及其制备方法，方案设计为多层复合地毯，其中地毯最上层为针刺面毯，该层作为装饰层，实际可根据需要选择针刺面毯的材质，也可根据需要将针刺面毯替换为簇绒面毯；针刺面毯下方为聚乙烯胶板，聚乙烯胶板作为骨架层，能够使地毯保持挺括，不易变形，而且聚乙烯胶板的设计也能够保证地毯的力学性能；聚乙烯胶板下方设计了无纺布，无纺布作为间隔层，无纺布另一侧发泡形成聚氨酯发泡层，聚氨酯发泡层作为隔音层，能够保证地毯的隔音效果；最底层为聚乙烯保护膜，聚乙烯保护膜具有较优异的强度和耐磨性能，能够对聚氨酯发泡层进行保护。
在该方案基础上，为提高行李箱地毯的抗菌、阻燃性能，本方案对制备工艺进行改进，将针刺面毯、无纺布和保护膜分别浸渍于阻燃浸渍液中进行预处理，得到预处理针刺面毯、预处理无纺布和预处理保护膜；再以预处理针刺面毯、聚乙烯胶板、预处理无纺布、聚氨酯发泡层、预处理保护膜的顺序制备地毯基体，地毯基体置于抗菌浸渍液中浸渍，紫外照射，由于阻燃浸渍液为含有巯基的丙烯酸酯共聚乳液，其中的巯基可在紫外光照射条件下与抗菌浸渍液中的双键发生反应，从而提高抗菌浸渍液的浸渍效果；抗菌浸渍液中含有3-烯丙基-5,5-二甲基海因、乙烯基封端的聚二甲基硅氧烷，3-烯丙基-5,5-二甲基海因具有较优异的抗菌性能，而乙烯基封端的聚二甲基硅氧烷能提高地毯表面的疏水性，因此得到的地毯具有较优异的抗菌性能，表面疏水性能较优异。
方案中，为制备含有巯基的丙烯酸酯共聚乳液，本方案先以取3-巯基丙酸、季戊四醇酯化反应生成季戊四醇酯，此处需限定“所述3-巯基丙酸与季戊四醇的摩尔比为1：(2～3)”，在该限定条件下，季戊四醇的羟基并不会反应完全，此时产物季戊四醇酯不仅含有巯基，还含有残留的羟基；接着方案将季戊四醇酯、丙烯酸羟乙酯、六氯环三磷腈等组分反应生成磷腈阻燃单体，在该反应过程中，季戊四醇酯中未反应的羟基、丙烯酸羟乙酯均可与六氯环三磷腈接枝反应，六氯环三磷腈的引入能够保证产品的阻燃性能；丙烯酸羟乙酯的接枝能够提高阻燃单体与后续丙烯酸酯共聚溶液的相容性，同时使得阻燃单体能够参与丙烯酸酯共聚，以保证阻燃浸渍液的浸渍效果。
同时，在制备阻燃浸渍液时，方案中引入了氧化石墨烯，氧化石墨烯的引入能够提高无纺布、针刺面毯和聚乙烯膜的表面耐磨损性能，以提高地毯的使用寿命，实用性更好。
本申请公开了一种耐磨聚氨酯行李箱地毯及其制备方法，工艺设计合理，组分配比适宜，制备得到的地毯具有多层复合结构，聚氨酯发泡层的存在使地毯具有较好的隔音效果，同时地毯具有优异的阻燃性能和抗菌性能，耐磨损性能较好，实用性高。
具体实施方式
下面将对本发明实施例中的技术方案进行清楚、完整地描述，显然，所描述的实施例仅仅是本发明一部分实施例，而不是全部的实施例。基于本发明中的实施例，本领域普通技术人员在没有做出创造性劳动前提下所获得的所有其他实施例，都属于本发明保护的范围。
以下实施例、对比例中，所述无纺布为PET无纺布，克重为100g/m2，厚度为2mm；所述针刺面毯的克重为500g/m2，厚度为10mm；所述聚氨酯发泡层的密度为45kg/m3，厚度为40mm；所述聚乙烯胶板的密度为4kg/m3，厚度为3mm；所述保护膜为聚乙烯膜，厚度为300μm。
所述扩链剂为1,4-丁二醇；所述发泡剂为水；所述泡沫稳定剂为羟基硅油。所述乙烯基封端的聚二甲基硅氧烷购买自北京百灵威科技有限公司。
实施例1：
一种耐磨聚氨酯行李箱地毯的制备方法，包括以下步骤：
(1)取针刺面毯、无纺布和保护膜，分别置于阻燃浸渍液中浸渍1h，取出后在90℃下真空干燥，分别得到预处理针刺面毯、预处理无纺布和预处理保护膜；所述阻燃浸渍液为含有巯基的丙烯酸酯共聚乳液；针刺面毯、无纺布和保护膜在进行预处理时，浴比均为1：10。
取预处理针刺面毯、聚乙烯胶板和预处理无纺布，以自上而下依次为预处理针刺面毯、聚乙烯胶板、预处理无纺布的顺序叠放，复合，形成地毯片；
(2)以质量计，取10份聚酯多元醇、70份聚醚多元醇、5份扩链剂、3份发泡剂、0.5份三乙醇胺和4份泡沫稳定剂，30℃下混合均匀，得到A料；取20份二苯基甲烷二异氰酸酯、20份甲苯二异氰酸酯混合，得到B料；
将A料、B料混合，搅拌均匀，形成发泡料；将地毯片吸附至发泡模具中，并注入发泡料发泡，脱模，在地毯片的无纺布一侧发泡形成聚氨酯发泡层，再在聚氨酯发泡层表面复合预处理保护膜，形成地毯基体；
(3)取3-烯丙基-5,5-二甲基海因、乙烯基封端的聚二甲基硅氧烷和丙酮混合，得到混合液，所述混合液浓度40g/L，混合液中加入安息香双甲醚，避光搅拌均匀，得到抗菌浸渍液；所述3-烯丙基-5,5-二甲基海因、乙烯基封端的聚二甲基硅氧烷的质量比为3：2；所述安息香双甲醚的用量为3-烯丙基-5,5-二甲基海因的3wt％。
将地毯基体转移至抗菌浸渍液中浸渍，浸渍时浴比为1：10；365nm紫外照射10min，取出，依次采用乙醇、去离子水洗涤，真空干燥，得到成品。
实施例2：
一种耐磨聚氨酯行李箱地毯的制备方法，包括以下步骤：
(1)取针刺面毯、无纺布和保护膜，分别置于阻燃浸渍液中浸渍1.5h，取出后在95℃下真空干燥，分别得到预处理针刺面毯、预处理无纺布和预处理保护膜；所述阻燃浸渍液为含有巯基的丙烯酸酯共聚乳液；针刺面毯、无纺布和保护膜在进行预处理时，浴比均为1：10。
取预处理针刺面毯、聚乙烯胶板和预处理无纺布，以自上而下依次为预处理针刺面毯、聚乙烯胶板、预处理无纺布的顺序叠放，复合，形成地毯片；
(2)以质量计，取16份聚酯多元醇、75份聚醚多元醇、8份扩链剂、3.5份发泡剂、0.8份三乙醇胺和5份泡沫稳定剂，35℃下混合均匀，得到A料；取25份二苯基甲烷二异氰酸酯、25份甲苯二异氰酸酯混合，得到B料；
将A料、B料混合，搅拌均匀，形成发泡料；将地毯片吸附至发泡模具中，并注入发泡料发泡，脱模，在地毯片的无纺布一侧发泡形成聚氨酯发泡层，再在聚氨酯发泡层表面复合预处理保护膜，形成地毯基体；
(3)取3-烯丙基-5,5-二甲基海因、乙烯基封端的聚二甲基硅氧烷和丙酮混合，得到混合液，所述混合液浓度40g/L，混合液中加入安息香双甲醚，避光搅拌均匀，得到抗菌浸渍液；所述3-烯丙基-5,5-二甲基海因、乙烯基封端的聚二甲基硅氧烷的质量比为3：2；所述安息香双甲醚的用量为3-烯丙基-5,5-二甲基海因的3wt％。
将地毯基体转移至抗菌浸渍液中浸渍，浸渍时浴比为1：10；365nm紫外照射15min，取出，依次采用乙醇、去离子水洗涤，真空干燥，得到成品。
实施例3：
一种耐磨聚氨酯行李箱地毯的制备方法，包括以下步骤：
(1)取针刺面毯、无纺布和保护膜，分别置于阻燃浸渍液中浸渍2h，取出后在100℃下真空干燥，分别得到预处理针刺面毯、预处理无纺布和预处理保护膜；所述阻燃浸渍液为含有巯基的丙烯酸酯共聚乳液；针刺面毯、无纺布和保护膜在进行预处理时，浴比均为1：10。
取预处理针刺面毯、聚乙烯胶板和预处理无纺布，以自上而下依次为预处理针刺面毯、聚乙烯胶板、预处理无纺布的顺序叠放，复合，形成地毯片；
(2)以质量计，取20份聚酯多元醇、80份聚醚多元醇、10份扩链剂、4份发泡剂、1份三乙醇胺和6份泡沫稳定剂，40℃下混合均匀，得到A料；取30份二苯基甲烷二异氰酸酯、30份甲苯二异氰酸酯混合，得到B料；
将A料、B料混合，搅拌均匀，形成发泡料；将地毯片吸附至发泡模具中，并注入发泡料发泡，脱模，在地毯片的无纺布一侧发泡形成聚氨酯发泡层，再在聚氨酯发泡层表面复合预处理保护膜，形成地毯基体；
(3)取3-烯丙基-5,5-二甲基海因、乙烯基封端的聚二甲基硅氧烷和丙酮混合，得到混合液，所述混合液浓度40g/L，混合液中加入安息香双甲醚，避光搅拌均匀，得到抗菌浸渍液；所述3-烯丙基-5,5-二甲基海因、乙烯基封端的聚二甲基硅氧烷的质量比为3：2；所述安息香双甲醚的用量为3-烯丙基-5,5-二甲基海因的3wt％。
将地毯基体转移至抗菌浸渍液中浸渍，浸渍时浴比为1：10；365nm紫外照射15min，取出，依次采用乙醇、去离子水洗涤，真空干燥，得到成品。
以上实施例1～3中，阻燃浸渍液的制备方法为：
S1：取3-巯基丙酸、季戊四醇和对甲苯磺酸，混合均匀，加热至90℃，反应5.5h，反应结束后收集产物，去离子水洗涤，减压蒸馏除水，得到季戊四醇酯；所述3-巯基丙酸与季戊四醇的摩尔比为1：3；所述对甲苯磺酸的用量为季戊四醇的5wt％。
S2：取季戊四醇酯、丙烯酸羟乙酯、氢氧化钠、六氯环三磷腈混合，加入四氢呋喃，油浴升温至90℃，回流搅拌反应10h，反应后静置冷却，抽滤收集产物，依次采用乙醇、去离子水洗涤，真空干燥，得到磷腈阻燃单体；所述季戊四醇酯、六氯环三磷腈、丙烯酸羟乙酯的摩尔比为1：2：7；所述氢氧化钠与季戊四醇酯的摩尔比为1：1.5。
S3：取丙烯酸酯单体、磷腈阻燃单体、十二烷基硫酸钠和去离子水，剪切乳化30min，加热升温至90℃，加入过硫酸钾，反应2h，再加入氧化石墨烯，搅拌反应40min，得到阻燃浸渍液；所述丙烯酸酯单体包括丙烯酸甲酯、丙烯酸丁酯、甲基丙烯酸三氟乙酯和丙烯酸羟乙酯；所述丙烯酸甲酯、丙烯酸丁酯、甲基丙烯酸三氟乙酯、丙烯酸羟乙酯的质量比为6：6：3：2。
所述丙烯酸酯单体、磷腈阻燃单体、去离子水的质量比为6：3：7；所述十二烷基硫酸钠的用量为丙烯酸酯单体、磷腈阻燃单体总量的4wt％；所述过硫酸钾的用量为丙烯酸酯单体、磷腈阻燃单体总量的3wt％；所述氧化石墨烯的用量为阻燃浸渍液的4wt％。
实施例4：实施例4以实施例3为对照，实施例4中调整阻燃浸渍液的各组分用量，其余步骤和参数一致。
实施例4中，阻燃浸渍液的制备方法为：
S1：取3-巯基丙酸、季戊四醇和对甲苯磺酸，混合均匀，加热至95℃，反应5h，反应结束后收集产物，去离子水洗涤，减压蒸馏除水，得到季戊四醇酯；所述3-巯基丙酸与季戊四醇的摩尔比为1：3；所述对甲苯磺酸的用量为季戊四醇的5wt％。
S2：取季戊四醇酯、丙烯酸羟乙酯、氢氧化钠、六氯环三磷腈混合，加入四氢呋喃，油浴升温至100℃，回流搅拌反应12h，反应后静置冷却，抽滤收集产物，依次采用乙醇、去离子水洗涤，真空干燥，得到磷腈阻燃单体；所述季戊四醇酯、六氯环三磷腈、丙烯酸羟乙酯的摩尔比为1：2：7；所述氢氧化钠与季戊四醇酯的摩尔比为1：1.5。
S3：取丙烯酸酯单体、磷腈阻燃单体、十二烷基硫酸钠和去离子水，剪切乳化30min，加热升温至90℃，加入过硫酸钾，反应3h，再加入氧化石墨烯，搅拌反应40min，得到阻燃浸渍液；所述丙烯酸酯单体包括丙烯酸甲酯、丙烯酸丁酯、甲基丙烯酸三氟乙酯和丙烯酸羟乙酯；所述丙烯酸甲酯、丙烯酸丁酯、甲基丙烯酸三氟乙酯、丙烯酸羟乙酯的质量比为6：6：3：2。
所述丙烯酸酯单体、磷腈阻燃单体、去离子水的质量比为6：3：7；所述十二烷基硫酸钠的用量为丙烯酸酯单体、磷腈阻燃单体总量的5wt％；所述过硫酸钾的用量为丙烯酸酯单体、磷腈阻燃单体总量的2wt％；所述氧化石墨烯的用量为阻燃浸渍液的4wt％。
对比例1：对比例1以实施例3为对照，对比例1中并未引入氧化石墨烯，其余步骤和参数一致。
具体调整的步骤为：S3：取丙烯酸酯单体、磷腈阻燃单体、十二烷基硫酸钠和去离子水，剪切乳化30min，加热升温至90℃，加入过硫酸钾，反应2h，得到阻燃浸渍液；所述丙烯酸酯单体包括丙烯酸甲酯、丙烯酸丁酯、甲基丙烯酸三氟乙酯和丙烯酸羟乙酯；所述丙烯酸甲酯、丙烯酸丁酯、甲基丙烯酸三氟乙酯、丙烯酸羟乙酯的质量比为6：6：3：2。
所述丙烯酸酯单体、磷腈阻燃单体、去离子水的质量比为6：3：7；所述十二烷基硫酸钠的用量为丙烯酸酯单体、磷腈阻燃单体总量的4wt％；所述过硫酸钾的用量为丙烯酸酯单体、磷腈阻燃单体总量的3wt％。
对比例2：对比例2以实施例3为对照，对比例2中调整阻燃浸渍液的制备步骤，其余步骤和参数一致。
具体调整的步骤为：S1：取3-巯基丙酸、季戊四醇和对甲苯磺酸，混合均匀，加热至90℃，反应5.5h，反应结束后收集产物，去离子水洗涤，减压蒸馏除水，得到季戊四醇酯；所述3-巯基丙酸与季戊四醇的摩尔比为1：4.5；所述对甲苯磺酸的用量为季戊四醇的5wt％。
对比例3：对比例3以实施例3为对照，对比例3中并未引入六氯环三磷腈，其余步骤和参数一致。
具体调整的步骤为：
S2：取季戊四醇酯、丙烯酸羟乙酯、氢氧化钠混合，加入四氢呋喃，油浴升温至90℃，回流搅拌反应10h，反应后静置冷却，抽滤收集产物，依次采用乙醇、去离子水洗涤，真空干燥，得到单体A；所述季戊四醇酯、丙烯酸羟乙酯的摩尔比为1：7；所述氢氧化钠与季戊四醇酯的摩尔比为1：1.5。
S3：取丙烯酸酯单体、单体A、十二烷基硫酸钠和去离子水，剪切乳化30min，加热升温至90℃，加入过硫酸钾，反应2h，再加入氧化石墨烯，搅拌反应40min，得到阻燃浸渍液；所述丙烯酸酯单体包括丙烯酸甲酯、丙烯酸丁酯、甲基丙烯酸三氟乙酯和丙烯酸羟乙酯；所述丙烯酸甲酯、丙烯酸丁酯、甲基丙烯酸三氟乙酯、丙烯酸羟乙酯的质量比为6：6：3：2。
所述丙烯酸酯单体、单体A、去离子水的质量比为6：3：7；所述十二烷基硫酸钠的用量为丙烯酸酯单体、单体A总量的4wt％；所述过硫酸钾的用量为丙烯酸酯单体、单体A总量的3wt％；所述氧化石墨烯的用量为阻燃浸渍液的4wt％。
对比例4：对比例4以实施例3为对照，对比例4中并未引入丙烯酸羟乙酯，其余步骤和参数一致。
具体调整的步骤为：
S2：取季戊四醇酯、氢氧化钠、六氯环三磷腈混合，加入四氢呋喃，油浴升温至90℃，回流搅拌反应10h，反应后静置冷却，抽滤收集产物，依次采用乙醇、去离子水洗涤，真空干燥，得到磷腈阻燃单体；所述季戊四醇酯、六氯环三磷腈的摩尔比为1：2；所述氢氧化钠与季戊四醇酯的摩尔比为1：1.5。
对比例5：对比例5以实施例3为对照，对比例5中并未浸渍抗菌浸渍液，其余步骤和参数一致。
一种耐磨聚氨酯行李箱地毯的制备方法，包括以下步骤：
(1)取针刺面毯、无纺布和保护膜，分别置于阻燃浸渍液中浸渍2h，取出后在100℃下真空干燥，分别得到预处理针刺面毯、预处理无纺布和预处理保护膜；所述阻燃浸渍液为含有巯基的丙烯酸酯共聚乳液；针刺面毯、无纺布和保护膜在进行预处理时，浴比均为1：10。
取预处理针刺面毯、聚乙烯胶板和预处理无纺布，以自上而下依次为预处理针刺面毯、聚乙烯胶板、预处理无纺布的顺序叠放，复合，形成地毯片；
(2)以质量计，取20份聚酯多元醇、80份聚醚多元醇、10份扩链剂、4份发泡剂、1份三乙醇胺和6份泡沫稳定剂，40℃下混合均匀，得到A料；取30份二苯基甲烷二异氰酸酯、30份甲苯二异氰酸酯混合，得到B料；
将A料、B料混合，搅拌均匀，形成发泡料；将地毯片吸附至发泡模具中，并注入发泡料发泡，脱模，在地毯片的无纺布一侧发泡形成聚氨酯发泡层，再在聚氨酯发泡层表面复合预处理保护膜，得到成品。
对比例6：对比例6以实施例3为对照，对比例6中并未浸渍阻燃浸渍液，其余步骤和参数一致。
一种耐磨聚氨酯行李箱地毯的制备方法，包括以下步骤：
(1)取针刺面毯、聚乙烯胶板和无纺布，以自上而下依次为针刺面毯、聚乙烯胶板、无纺布的顺序叠放，复合，形成地毯片；
(2)以质量计，取20份聚酯多元醇、80份聚醚多元醇、10份扩链剂、4份发泡剂、1份三乙醇胺和6份泡沫稳定剂，40℃下混合均匀，得到A料；取30份二苯基甲烷二异氰酸酯、30份甲苯二异氰酸酯混合，得到B料；
将A料、B料混合，搅拌均匀，形成发泡料；将地毯片吸附至发泡模具中，并注入发泡料发泡，脱模，在地毯片的无纺布一侧发泡形成聚氨酯发泡层，再在聚氨酯发泡层表面复合保护膜，形成地毯基体；
(3)取3-烯丙基-5,5-二甲基海因、乙烯基封端的聚二甲基硅氧烷和丙酮混合，得到混合液，所述混合液浓度40g/L，混合液中加入安息香双甲醚，避光搅拌均匀，得到抗菌浸渍液；所述3-烯丙基-5,5-二甲基海因、乙烯基封端的聚二甲基硅氧烷的质量比为3：2；所述安息香双甲醚的用量为3-烯丙基-5,5-二甲基海因的3wt％。
将地毯基体转移至抗菌浸渍液中浸渍，浸渍时浴比为1：10；365nm紫外照射15min，取出，依次采用乙醇、去离子水洗涤，真空干燥，得到成品。
检测实验：
1、取实施例1-4制备的行李箱地毯，制成尺寸为1200mm×600mm×50mm的地毯样品，按照GB/T 18686.1-2004《声学阻抗管中吸声系数和声阻抗的测量第1部分：驻波比法》公开的方法测试地毯的隔音效果，并记录检测数据。
Figure BDA0003919478900000111
2、取实施例3-4、对比例1-6制备的行李箱地毯，按照GB/T 20944.3-2008《纺织品抗菌性能的评价第3部分：振荡法》公开的测试方法检测地毯的抗菌性能，测试菌种为大肠杆菌。
3、取实施例3-4、对比例1-6制备的行李箱地毯，对行李箱地毯的聚乙烯保护膜一侧进行检测，测试其水接触角，测试时水滴大小控制为6μL，在聚乙烯保护膜不同的位置测试五次，计算平均值，并记录。
项目 实施例3 对比例1 对比例2 对比例3 对比例4 对比例5 对比例6
抗菌率 99.9％ 99.9％ 99.9％ 99.9％ 99.9％ 73.4％ 99.8％
极限氧指数 32 31 24 23 30 31 22
水接触角 154° 153° 152° 152° 151° 128° 147°
结论：本申请工艺设计合理，组分配比适宜，制备得到的地毯具有多层复合结构，聚氨酯发泡层的存在使地毯具有较好的隔音效果，同时地毯具有优异的阻燃性能和抗菌性能，耐磨损性能较好，实用性高。
最后应说明的是：以上所述仅为本发明的优选实施例而已，并不用于限制本发明，尽管参照前述实施例对本发明进行了详细的说明，对于本领域的技术人员来说，其依然可以对前述各实施例所记载的技术方案进行修改，或者对其中部分技术特征进行等同替换。凡在本发明的精神和原则之内，所作的任何修改、等同替换、改进等，均应包含在本发明的保护范围之内。

Claims (9)

1.一种耐磨聚氨酯行李箱地毯的制备方法，其特征在于：包括以下步骤：
(1)取针刺面毯、无纺布和保护膜，分别置于阻燃浸渍液中浸渍1～2h，取出后真空干燥，分别得到预处理针刺面毯、预处理无纺布和预处理保护膜；所述阻燃浸渍液为含有巯基的丙烯酸酯共聚乳液；
取预处理针刺面毯、聚乙烯胶板和预处理无纺布，以自上而下依次为预处理针刺面毯、聚乙烯胶板、预处理无纺布的顺序叠放，复合，形成地毯片；
(2)取聚酯多元醇、聚醚多元醇、扩链剂、发泡剂、三乙醇胺和泡沫稳定剂，30～40℃下混合均匀，得到A料；取二苯基甲烷二异氰酸酯、甲苯二异氰酸酯混合，得到B料；
将A料、B料混合，搅拌均匀，形成发泡料；将地毯片吸附至发泡模具中，并注入发泡料发泡，脱模，在地毯片的无纺布一侧发泡形成聚氨酯发泡层，再在聚氨酯发泡层表面复合预处理保护膜，形成地毯基体；
(3)取3-烯丙基-5,5-二甲基海因、乙烯基封端的聚二甲基硅氧烷和丙酮混合，加入安息香双甲醚，避光搅拌均匀，得到抗菌浸渍液；
将地毯基体转移至抗菌浸渍液中浸渍，紫外照射10～15min，取出，依次采用乙醇、去离子水洗涤，真空干燥，得到成品。
2.根据权利要求1所述的一种耐磨聚氨酯行李箱地毯的制备方法，其特征在于：步骤(2)中，各组分含量为：以质量计，聚酯多元醇10～20份、聚醚多元醇70～80份、二苯基甲烷二异氰酸酯20～30份、甲苯二异氰酸酯20～30份、扩链剂5～10份、发泡剂3～4份、三乙醇胺0.5～1份、泡沫稳定剂4～6份。
3.根据权利要求2所述的一种耐磨聚氨酯行李箱地毯的制备方法，其特征在于：所述扩链剂为1,4-丁二醇、丙三醇、丙二醇中的任意一种；所述发泡剂为水；所述泡沫稳定剂为羟基硅油。
4.根据权利要求1所述的一种耐磨聚氨酯行李箱地毯的制备方法，其特征在于：所述无纺布为PET无纺布，克重为80～100g/m2，厚度为1～2mm；所述针刺面毯的克重为400～600g/m2，厚度为8～10mm；所述聚氨酯发泡层的密度为40～50kg/m3，厚度为30～40mm；所述聚乙烯胶板的密度为3～4kg/m3，厚度为2～3mm；所述保护膜为聚乙烯膜。
5.根据权利要求1所述的一种耐磨聚氨酯行李箱地毯的制备方法，其特征在于：步骤(1)中，所述阻燃浸渍液的制备方法为：
S1：取3-巯基丙酸、季戊四醇和对甲苯磺酸，混合均匀，加热至85～95℃，反应5～6h，反应结束后收集产物，去离子水洗涤，减压蒸馏除水，得到季戊四醇酯；
S2：取季戊四醇酯、丙烯酸羟乙酯、氢氧化钠、六氯环三磷腈混合，加入四氢呋喃，油浴升温至90～100℃，回流搅拌反应8～12h，反应后静置冷却，抽滤收集产物，依次采用乙醇、去离子水洗涤，真空干燥，得到磷腈阻燃单体；
S3：取丙烯酸酯单体、磷腈阻燃单体、十二烷基硫酸钠和去离子水，剪切乳化20～30min，加热升温至80～90℃，加入过硫酸钾，反应2～3h，再加入氧化石墨烯，搅拌反应30-40min，得到阻燃浸渍液；所述丙烯酸酯单体包括丙烯酸甲酯、丙烯酸丁酯、甲基丙烯酸三氟乙酯和丙烯酸羟乙酯。
6.根据权利要求5所述的一种耐磨聚氨酯行李箱地毯的制备方法，其特征在于：步骤S3中，所述丙烯酸甲酯、丙烯酸丁酯、甲基丙烯酸三氟乙酯、丙烯酸羟乙酯的质量比为6：6：3：2；所述丙烯酸酯单体、磷腈阻燃单体、去离子水的质量比为6：3：7；所述十二烷基硫酸钠的用量为丙烯酸酯单体、磷腈阻燃单体总量的3～5wt％；所述过硫酸钾的用量为丙烯酸酯单体、磷腈阻燃单体总量的2～3wt％。
7.根据权利要求5所述的一种耐磨聚氨酯行李箱地毯的制备方法，其特征在于：步骤S1中，所述3-巯基丙酸与季戊四醇的摩尔比为1：(2～3)；
步骤S2中，所述季戊四醇酯、六氯环三磷腈、丙烯酸羟乙酯的摩尔比为1：2：(6～7)。
8.根据权利要求1所述的一种耐磨聚氨酯行李箱地毯的制备方法，其特征在于：步骤(3)中，所述3-烯丙基-5,5-二甲基海因、乙烯基封端的聚二甲基硅氧烷的质量比为3：2；所述安息香双甲醚的用量为3-烯丙基-5,5-二甲基海因的2～3wt％。
9.根据权利要求1～8中任一项所述的一种耐磨聚氨酯行李箱地毯的制备方法制备的行李箱地毯。
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