阅读说明：本技术 一种阻燃复合材料及其制备方法 (Flame-retardant composite material and preparation method thereof ) 是由 陈志伟 金震宇 于 2020-12-31 设计创作，主要内容包括：本发明公开了一种阻燃复合材料,依次包括外层、中间层和内层,所述外层为皮革或面料,所述中间层为阻燃非织造材料,所述内层为含有低熔点涤纶纤维的材料；所述外层与中间层之间采用阻燃胶水进行粘接,所述中间层与内层之间采用热压进行粘接。本发明的阻燃复合材料,通过在内层中添加一定比例的低熔点涤纶纤维,使得内层与中间层之间采用液压的方式进行粘接,避免了胶水的使用,进一步提升了阻燃的效果,也降低了成本,使得制备得到的阻燃复合材料的极限氧指数满足营运公交车辆对纺织材料的阻燃要求。(The invention discloses a flame-retardant composite material, which sequentially comprises an outer layer, a middle layer and an inner layer, wherein the outer layer is made of leather or fabric, the middle layer is made of a flame-retardant non-woven material, and the inner layer is made of a material containing low-melting-point polyester fibers; the outer layer and the middle layer are bonded by adopting flame-retardant glue, and the middle layer and the inner layer are bonded by adopting hot pressing. According to the flame-retardant composite material, the low-melting-point polyester fiber is added into the inner layer in a certain proportion, so that the inner layer and the middle layer are bonded in a hydraulic manner, the use of glue is avoided, the flame-retardant effect is further improved, the cost is also reduced, and the limit oxygen index of the prepared flame-retardant composite material meets the flame-retardant requirement of a commercial bus on a textile material.)

1. The flame-retardant composite material is characterized by sequentially comprising an outer layer, a middle layer and an inner layer, wherein the outer layer is made of leather or fabric, the middle layer is made of flame-retardant non-woven material, and the inner layer is made of material containing low-melting-point polyester fiber; the outer layer and the middle layer are bonded by adopting flame-retardant glue, and the middle layer and the inner layer are bonded by adopting hot pressing.

2. The flame-retardant composite material of claim 1, wherein the flame-retardant nonwoven material comprises the following raw material components in parts by weight: 30-40 parts of high-temperature low-melting-point polyester staple fibers, 10-20 parts of three-dimensional hollow polyester staple fibers, 20-40 parts of three-dimensional hollow fibers with contractibility and 20-40 parts of three-dimensional crimped hollow polyester staple fibers; the melting point of the high-temperature low-melting-point polyester staple fiber is more than or equal to 160 ℃; the shrinkage rate of the three-dimensional hollow fiber with the contractility is 5-10% at 180 ℃ for 15 min.

3. The flame-retardant composite material according to claim 2, wherein the flame-retardant nonwoven material comprises fibers having a thickness of less than 5D in the raw material in an amount of 80% or more by mass.

4. The flame-retardant composite material according to claim 3, wherein the high-temperature low-melting-point polyester staple fibers, the three-dimensional hollow fibers with contractility and the three-dimensional crimped hollow polyester staple fibers have a thickness of 2-4D; the thickness of the three-dimensional hollow polyester staple fiber is greater than or equal to 5D.

5. The flame retardant composite of claim 2 wherein the raw materials used in the flame retardant nonwoven are all three dimensional fibers.

6. The flame retardant composite of claim 1 wherein the high temperature low melting point polyester staple fibers have a thickness and length of 2D x 51 mm; the thickness and the length of the three-dimensional hollow polyester staple fiber are 7D and 51-88 mm; the three-dimensional hollow fiber with contractility has the thickness and the length of 3D 51-88 mm, and the thickness and the length of the three-dimensional curled hollow polyester staple fiber are 3D 51-88 mm.

7. Flame retardant according to claim 6The composite material is characterized in that the inner layer is a net lining, spunlace or needle-punched cloth containing low-melting point polyester staple fibers; the density of the mesh lining is 10-30 g/m²。

8. The flame-retardant composite material according to claim 1, wherein the spunlace or needle-punched fabric comprises 5-30% by mass of 2-4D 51mm low-melting point polyester staple fibers.

9. The flame-retardant composite material according to claim 1, wherein the low-melting-point short fiber has a melting point of 110 to 120 ℃.

10. A method of preparing a flame retardant composite according to any of claims 1 to 9, comprising the steps of:

1) preparing a flame-retardant non-woven material: sequentially opening, mixing, carding, lapping, vertically forming, hot air setting, cutting, rolling, cutting and rolling a plurality of fiber raw materials of the flame-retardant non-woven material to obtain the non-woven material;

2) bonding the flame-retardant non-woven material of the middle layer with the inner layer in a hot-pressing mode; and then, adhering the other side of the middle layer with the outer layer by adopting flame-retardant glue to obtain the flame-retardant composite material.

Technical Field

The invention relates to the technical field of flame-retardant materials, in particular to a flame-retardant composite material suitable for automotive interior and a preparation method of the flame-retardant composite material.

Background

In recent years, the burning accidents of the vehicle interior trim are frequent, particularly, the composite with the cushion filler has a plurality of people's dead injury cases caused by fire. In the application fields of seats, ceilings, door plates, safety seats, sofas, soft chairs, deck chairs and the like of high-speed rails, motor cars, city railways, passenger cars and cars, the improvement of the flame retardant property of leather and textile composite materials is urgent. Therefore, China also develops a plurality of mandatory national standards and industrial standards, such as GB8410-2006, GB38262-2019, JT/T1095-2016, TB/T3237-2010 and the like, and the requirements of industry and products are enhanced so as to reduce the problem caused by material problems and expand the problems.

PU sponge has many advantages in the vehicle application process, and the material is soft, the resilience is good, advantages such as low price, but also has many shortcomings: large peculiar smell, difficult standard-reaching flame retardance, easy aging and the like. Therefore, how to improve the problem of difficult flame retardance of the PU sponge on the premise of ensuring that the material has the advantages of the PU sponge is a research hotspot in the industry at present.

Disclosure of Invention

In view of the above, in order to overcome the defects of the prior art, the present invention aims to provide an improved flame retardant composite material, which can meet the flame retardant requirements of automotive interior.

In order to achieve the purpose, the invention adopts the following technical scheme:

the flame-retardant composite material sequentially comprises an outer layer, a middle layer and an inner layer, wherein the outer layer is made of leather or fabric, the middle layer is made of a flame-retardant non-woven material, and the inner layer is made of a material containing low-melting-point polyester fibers; the outer layer and the middle layer are bonded by adopting flame-retardant glue, and the middle layer and the inner layer are bonded by adopting hot pressing.

Through adding a certain proportion of low-melting-point polyester fiber in the inner layer, the inner layer is bonded with the middle layer in a hydraulic mode, so that the process is simplified, the use of glue is avoided, the flame-retardant effect is further improved, and the cost is reduced. When the adhesive is prepared, the middle layer and the inner layer are hot-ironed and bonded to have certain strength in the longitudinal direction, and then the other side of the middle layer is bonded with the outer layer. Through the arrangement of the materials and the structure, the limit oxygen index of the prepared flame-retardant composite material is between 28 and 39 percent, and the flame-retardant requirement of JT/T1095 and 2016 on the textile material for operating buses is met.

According to some preferred embodiments of the present invention, the flame retardant nonwoven material comprises the following raw material components in parts by weight: 30-40 parts of high-temperature low-melting-point polyester staple fibers, 10-20 parts of three-dimensional hollow polyester staple fibers, 20-40 parts of three-dimensional hollow fibers with contractibility and 20-40 parts of three-dimensional crimped hollow polyester staple fibers; the melting point of the high-temperature low-melting-point polyester staple fiber is more than or equal to 160 ℃; the shrinkage rate of the three-dimensional hollow fiber with the contractility in an oven at 180 ℃ for 15min is 5-10%. According to some preferred embodiments of the invention, the high temperature low melting point polyester staple fibers have a melting point of greater than or equal to 180 ℃.

After the high-temperature low-melting-point short fiber is prepared into a product, the product is compounded and synergistic with other types of short fibers, and the flame retardant effect and TVOC effect of the product are better. The three-dimensional hollow polyester fiber with larger contractibility is added, so that the prepared product is more compact and has better flame retardant effect.

According to some preferred embodiment aspects of the present invention, the flame-retardant nonwoven material has a mass ratio of fibers having a coarseness of less than 5D in the raw material to the flame-retardant nonwoven material of 80% or more. That is, the mass ratio of 2-4D short fibers to the nonwoven material is 80% or more, and the mass ratio of 5D or more coarse fibers to the nonwoven material is 20% or less. By controlling the proportion of the coarse fibers, the gap rate of the product is reduced, and the flame retardant effect of the product is improved. If the too coarse fiber accounts for a large proportion, the higher the gap rate of the product is, more air can be contained, the combustion speed is high, and the flame retardant effect is poor.

According to some preferred embodiments of the present invention, the high-temperature low-melting point polyester staple fiber, the three-dimensional hollow fiber having contractility, and the three-dimensional crimped hollow polyester staple fiber have a thickness of 2 to 4D and a length of 51 to 88 mm; the thickness of the three-dimensional hollow polyester staple fiber is greater than or equal to 5D. In some embodiments of the present invention, it is preferable that the thickness of the three-dimensional hollow polyester staple fiber is greater than or equal to 7D. The use of coarse fibres is to give the product a certain stiffness.

According to some preferred embodiments of the present invention, the high temperature low melting point polyester staple fiber has a thickness of 2D; the thickness of the three-dimensional hollow fiber with contractility and the three-dimensional crimped hollow polyester staple fiber is 3D.

According to some preferred embodiments of the invention, the raw materials adopted in the flame-retardant non-woven material are all three-dimensional fibers and do not have two-dimensional fibers, so that the manufactured product has high structural tightness and high breaking strength, the flame-retardant effect is enhanced on one hand, the cut surface of the product has better smoothness and smoothness, and the surface smoothness and smoothness are high after the cotton is compounded with the relatively light and thin fabric glue.

According to some preferred embodiments of the invention, the high temperature low melting point polyester staple fibers have a thickness and length of 2D 51 mm; the thickness and the length of the three-dimensional hollow polyester staple fiber are 7D and 51-88 mm; the three-dimensional hollow fiber with contractility has the thickness and the length of 3D 51-88 mm, and the thickness and the length of the three-dimensional curled hollow polyester staple fiber are 3D 51-88 mm.

According to some preferred embodiments of the invention, the density of the flame retardant nonwoven material is 10 to 45g/m per mm²The non-woven material has a limiting oxygen index greater than or equal to 30%.

According to the application, through the matching of four short fibers (high-temperature low-melting-point polyester short fibers, three-dimensional hollow fibers with contractibility and three-dimensional curled hollow polyester short fibers), the melting point temperature of the high-temperature low-melting-point polyester short fibers, the proportion among fiber thicknesses and the fibers with contractibility are selected at the repeated points, the purpose that the prepared product has good flame retardant property on the premise of no flame retardant property fiber is achieved, and related physical properties such as elasticity and softness of the product are kept close to those of PU sponge.

The preparation method of the flame-retardant non-woven material comprises the following steps: the method comprises the following steps of sequentially opening, mixing, carding, lapping, vertically forming, hot air setting, cutting, rolling, cutting and rolling a plurality of fiber raw materials of the non-woven material to obtain the non-woven material. Wherein the vertical forming consists in folding the tissue web by a tissue web folding mechanism to resemble a folded fan leaf.

According to some preferred embodiments of the invention, the inner layer is a mesh liner, spunlace or needle-punched fabric containing low-melting polyester staple fibers; the density of the mesh lining is 10-30 g/m per millimeter²。

According to some preferred implementation aspects of the invention, the net lining is a polyester spun-bonded lining or a polyester hot-air cotton lining, and the raw material of the net lining comprises 15-100% by mass of 2-4D 51mm low-melting-point polyester staple fibers and the balance of 0.8-3D 38-88 mm other common polyester fibers.

According to some preferred embodiments of the present invention, the raw material of the spunlace or needle-punched cloth comprises 10 to 30% by mass of 2 to 4D 51mm low-melting point polyester staple fibers and the balance of 0.8 to 3D 38 to 88mm other common polyester fibers.

According to some preferred embodiments of the invention, the low-melting-point short fiber has a melting point of 110 to 120 ℃.

The invention also provides a preparation method of the flame-retardant composite material, which is characterized by comprising the following steps:

1) preparing a flame-retardant non-woven material: sequentially opening, mixing, carding, lapping, vertically forming, hot air setting, cutting, rolling, cutting and rolling a plurality of fiber raw materials of the flame-retardant non-woven material to obtain the non-woven material;

2) bonding the flame-retardant non-woven material of the middle layer with the inner layer in a hot-pressing mode; and then, adhering the other side of the middle layer with the outer layer by adopting flame-retardant glue to obtain the flame-retardant composite material. The temperature of the hot pressing roller during hot pressing is 170-190 ℃, and the rotating speed of the hot pressing roller is 5-15 m/min.

Due to the adoption of the technical scheme, compared with the prior art, the invention has the beneficial effects that: according to the flame-retardant composite material, the low-melting-point polyester fiber is added into the inner layer in a certain proportion, so that the inner layer and the middle layer are bonded in a hot-pressing mode, the use of glue is avoided, the flame-retardant effect is further improved, the cost is also reduced, and the limit oxygen index of the prepared flame-retardant composite material meets the flame-retardant requirement of a commercial bus on a textile material.

Detailed Description

In order to make those skilled in the art better understand the technical solution of the present invention, the technical solution in the embodiments of the present invention will be clearly and completely described below, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.

Example 1 flame retardant nonwoven Material

The flame-retardant nonwoven material of the present embodiment comprises, by mass, 40% of non-flame-retardant high-temperature low-melting-point (melting point 180 ℃) polyester staple fibers 2D × 51mm, 10% of non-flame-retardant three-dimensional hollow polyester staple fibers 7D × 51mm, 30% of shrinkable three-dimensional hollow fibers 3D × 51mm, and 20% of non-flame-retardant three-dimensional crimped hollow polyester staple fibers 3D × 51 mm.

A cotton sample having a thickness of 5mm and a density of 20g/m was prepared²The limiting oxygen index is 31%.

A cotton sample having a thickness of 8mm and a density of 25g/m was prepared²The limiting oxygen index is 34%.

Example 2 flame retardant nonwoven Material

The flame-retardant nonwoven material of the present embodiment comprises, by mass, 30% of non-flame-retardant high-temperature low-melting-point (melting point 180 ℃) polyester staple fibers 2D × 51mm, 10% of non-flame-retardant three-dimensional hollow polyester staple fibers 7D × 88mm, 40% of shrinkable three-dimensional hollow fibers 3D × 51mm, and 20% of non-flame-retardant three-dimensional crimped hollow polyester staple fibers 3D × 64 mm.

A cotton sample having a thickness of 5mm and a density of 20g/m was prepared²The limiting oxygen index is 33%.

A cotton sample having a thickness of 8mm and a density of 25g/m was prepared²The limiting oxygen index is 36%.

Example 3 flame retardant nonwoven Material

The flame-retardant nonwoven material of the present embodiment comprises, by mass, 30% of non-flame-retardant high-temperature low-melting-point (melting point 180 ℃) polyester staple fibers 2D × 51mm, 10% of non-flame-retardant three-dimensional hollow polyester staple fibers 7D × 51mm, 20% of shrinkable three-dimensional hollow fibers 3D × 51mm, and 40% of non-flame-retardant three-dimensional crimped hollow polyester staple fibers 3D × 88 mm.

A cotton sample having a thickness of 5mm and a density of 20g/m was prepared²The limiting oxygen index is 30%.

A cotton sample having a thickness of 8mm and a density of 25g/m was prepared²The limiting oxygen index is 33%.

The flame-retardant nonwoven material of embodiments 1 to 3 achieves a composite synergistic effect by matching the four types of short fibers (high-temperature low-melting point polyester short fibers, three-dimensional hollow fibers with contractibility, three-dimensional crimped hollow polyester short fibers), achieves a flame-retardant effect of a final product by using non-flame-retardant raw materials, and maintains the flame-retardant effect while still ensuring good cutting effect and breaking strength by the ratio of the four types of short fibers, and is low in cost.

Example 4 flame retardant composite

The flame retardant composite in this example includes an outer layer, an intermediate layer, and an inner layer. Wherein the content of the first and second substances,

the outer layer is PU leather for ordinary vehicles. The middle layer was a 5mm thick flame retardant nonwoven as in example 1. The inner layer is a net lining of a polyester hot-air cotton lining, and the raw materials comprise 15% by mass of 2D 51mm low-melting-point polyester staple fibers (melting point 120 ℃) and 85% by mass of 3D 88mm other common polyester fibers.

When the flame-retardant nonwoven material is prepared, one side of the flame-retardant nonwoven material of the middle layer and the net lining of the inner layer are hot-pressed at the temperature of 170 ℃ and the rotating speed of a hot-pressing roller of 10 m/min. And then, adhering the other side of the flame-retardant non-woven material with leather by adopting flame-retardant glue to obtain the flame-retardant composite material suitable for automotive interiors.

Example 5 flame retardant composite

The flame retardant composite in this example includes an outer layer, an intermediate layer, and an inner layer. Wherein the content of the first and second substances,

the outer layer is 300g/m²Raised flame-retardant fabric. The middle layer was a flame retardant nonwoven material of example 2 having a thickness of 5 mm. The inner layer is made of spunlace fabric, and the raw materials comprise 5% of 2D 51mm low-melting-point polyester staple fibers and 95% of 1.2D 51mm other common polyester fibers in mass ratio.

When the flame-retardant nonwoven material is prepared, one side of the flame-retardant nonwoven material of the middle layer and the mesh lining of the inner layer are hot-pressed at 185 ℃ and the rotating speed of a hot-pressing roller is 5 m/min. And then, adhering the other side of the flame-retardant non-woven material with leather by adopting flame-retardant glue to obtain the flame-retardant composite material suitable for automotive interiors.

Example 6 flame retardant composite

The flame retardant composite in this example includes an outer layer, an intermediate layer, and an inner layer. Wherein the content of the first and second substances,

the outer layer is PU leather for ordinary vehicles. The middle layer was a flame retardant nonwoven material of example 3 having a thickness of 5 mm. The inner layer is made of spunlace fabric, and the raw materials comprise 30% by mass of 2D 51mm low-melting point polyester staple fibers (melting point 120 ℃) and 70% by mass of 3D 88mm other common polyester fibers.

When the flame-retardant nonwoven material is prepared, one side of the flame-retardant nonwoven material of the middle layer and the net lining of the inner layer are hot-pressed at the temperature of 170 ℃ and the rotating speed of a hot-pressing roller of 10 m/min. And then, adhering the other side of the flame-retardant non-woven material with leather by adopting flame-retardant glue to obtain the flame-retardant composite material suitable for automotive interiors.

Comparative example 1

The composition ratio of the non-woven material in the comparative example was substantially the same as that in example 1, except that the non-flame-retardant three-dimensionally crimped hollow polyester staple fibers in the comparative example had a thickness of 5D × 64 mm.

Comparative example 2

The composition ratio of the nonwoven material in this comparative example was substantially the same as that in example 1, except that there was no shrinkable three-dimensional hollow fiber in this comparative example, and the non-flame-retardant three-dimensional crimped hollow polyester staple fiber was used instead. The nonwoven material of this comparative example includes, by mass ratio, 40% of non-flame-retardant high-temperature low-melting-point (melting point 180 ℃) polyester staple fibers 2D × 51mm, 10% of non-flame-retardant three-dimensional hollow polyester staple fibers 7D × 51mm, and 50% of non-flame-retardant three-dimensional crimped hollow polyester staple fibers 3D × 51 mm.

Comparative example 3

The composition ratio of the non-woven material in the comparative example is basically the same as that in the example 1, and the difference point is that the melting point temperature of the non-flame-retardant low-melting-point polyester staple fiber in the comparative example is 120 ℃.

Comparative example 4

The material of this comparative example had substantially the same composition and formulation as those of example 5, except that the composite material of this comparative example had no inner spunlace.

Testing and analysis

1. The nonwoven materials prepared in examples 1 to 3 and comparative examples 1 to 3 and the conventional PU sponge materials were subjected to the tests for density, surface hardness, ball rebound, odor and limiting oxygen index in this order, and the test results are shown in the following table:

table 1 test results of nonwoven materials

Serial number	Density of	Surface hardness	Rebound resilience of ball drop	Peculiar smell	Limiting oxygen index LOI
						Example 1	20D	60	45％	≥3.0	≥31％
Example 2	20D	65	42％	≥3.0	≥33％
						Example 3	20D	55	48％	≥3.0	≥30％
Common PU sponge	28D	70	43％	≥3.5	＜27％
						Comparative example 1	25D	62	42％	≥3.0	≥35％
Comparative example 2	20D	53	44％	≥3.0	≥28％
						Comparative example 3	25D	62	42％	≥3.0	≥26％

Table 1 shows that the non-woven material prepared in the embodiment 1-3 has good flame retardant effect, and the flame retardant value reaches the flame retardant requirement of JT/T1095-2016 on the automotive textile material; the hand feeling is soft and elastic, the vertical elasticity (ball rebound rate) is close to that of a sponge material and is superior to that of other non-woven materials; the weight per gram is light, the VOC and the peculiar smell are low, the peculiar smell grade is 3.0, the peculiar smell is far higher than that of other chemical foaming materials such as sponge and the like, and the peculiar smell is also obviously superior to that of other materials; is not easy to age and has low price.

2. The examples 4 to 6 and comparative example 4 were tested for flame retardant effect, and the test results are shown in Table 2:

TABLE 2 test results

Item	Effect of sewing process	Limiting oxygen index LOI
			Example 4	Easy sewing	31％
Example 5	Easy sewing	30％
			Example 6	Easy sewing	32％
Comparative example 4	High friction and uneasy sewing	26％

As can be seen from the implementation and the comparative example, the inner lining materials applied in the examples 4 to 6 have good effects, on one hand, the whole flame retardant effect is enhanced, and on the other hand, the rear-end sewing effect is also influenced to a certain extent.

The above embodiments are merely illustrative of the technical ideas and features of the present invention, and the purpose thereof is to enable those skilled in the art to understand the contents of the present invention and implement the present invention, and not to limit the protection scope of the present invention. All equivalent changes and modifications made according to the spirit of the present invention should be covered within the protection scope of the present invention.