CN114474907A

CN114474907A - Flame-retardant carpet and manufacturing method thereof

Info

Publication number: CN114474907A
Application number: CN202210097459.2A
Authority: CN
Inventors: 蒋宝林; 孙长庆; 杨冰; 张磊
Original assignee: Guangdong Huitian Aerospace Technology Co Ltd
Current assignee: Guangdong Huitian Aerospace Technology Co Ltd
Priority date: 2022-01-27
Filing date: 2022-01-27
Publication date: 2022-05-13

Abstract

The application provides a fire-retardant carpet and a manufacturing method of the fire-retardant carpet, the fire-retardant carpet comprises a napping surface layer, a sound insulation bonding layer, a base material layer and a fire-retardant bottom layer which are sequentially stacked, wherein the napping surface layer and the base material layer both comprise a fire-retardant PET fiber material and a low-melting-point PET fiber material, and the fire-retardant PET fiber material and the fire-retardant bottom layer are both fire-retardant by adopting phosphorus. The application provides a fire-retardant carpet, fire-retardant PET fiber material can improve the fire resistance, and low melting point PET fiber material plays the shaping effect for fire-retardant carpet not only can satisfy the fire-retardant requirement of aviation carpet, also can satisfy the shaping demand, thereby can be applicable to the air-ground amphibious manned vehicle.

Description

Flame-retardant carpet and manufacturing method thereof

Technical Field

The application relates to the technical field of carpets, in particular to a flame-retardant carpet and a manufacturing method of the flame-retardant carpet.

Background

An air-ground amphibious manned vehicle is a manned vehicle which can run on the ground and can also fly on the sky. However, at present, no carpet suitable for an air-ground amphibious manned aircraft exists so as to meet the design and use requirements under two working conditions of flight and land.

Disclosure of Invention

The present application is directed to a flame retardant carpet and a method for making the same to solve or improve the above-mentioned problems. The present application achieves the above object by the following technical solutions.

In a first aspect, the embodiment of the application provides a flame retardant carpet, including the pile top layer, the adhesive linkage that gives sound insulation, substrate layer and the fire-retardant bottom of stacking gradually arranging, wherein, pile top layer and substrate layer all include fire-retardant PET fiber material and low melting point PET fiber material, and fire-retardant PET fiber material and fire-retardant bottom all adopt phosphorus to be fire-retardant.

In a second aspect, embodiments of the present application provide a method for manufacturing a flame retardant carpet, the method comprising: mixing a low-melting-point PET fiber material and a flame-retardant PET fiber material adopting a phosphorus flame retardant, and then carrying out needle punching and raising to form a raised surface layer; attaching a sound-insulating adhesive layer to the bottom surface of the raised surface layer; mixing a low-melting-point PET fiber material and a flame-retardant PET fiber material adopting a phosphorus flame retardant to form a base material layer, and compounding the base material layer on the surface of the sound-insulation bonding layer, which is far away from the napping surface layer; and providing a flame-retardant bottom layer adopting phosphorus flame retardance, and compounding the flame-retardant bottom layer on the surface of the base material layer, which is far away from the sound-insulation bonding layer.

The flame-retardant carpet and the manufacturing method of the flame-retardant carpet provided by the embodiment of the application have the advantages that the napping surface layer can meet the requirements of a needling napping process of an air-ground amphibious manned aircraft, the napping surface layer and the base material layer both comprise the flame-retardant PET fiber material and the low-melting-point PET fiber material, the flame-retardant PET fiber material and the flame-retardant bottom layer are flame-retardant by adopting a phosphorus system, the requirements of relevant regulations under two working conditions of flight and ground are met, the flame retardance can be improved by the flame-retardant PET fiber material, the low-melting-point PET fiber material plays a forming role, so that the flame-retardant carpet can meet the flame-retardant requirements of the aviation carpet and can meet the forming requirements, and the flame-retardant carpet is suitable for the air-ground amphibious manned aircraft.

Drawings

In order to more clearly illustrate the technical solutions in the embodiments of the present application, the drawings required to be used in the description of the embodiments are briefly introduced below, and it is obvious that the drawings in the description below are only some embodiments of the present application, and it is obvious for those skilled in the art to obtain other drawings based on these drawings without creative efforts.

Fig. 1 is a schematic structural view of a flame retardant carpet provided in an embodiment of the present application.

Fig. 2 is a schematic structural view of a flame retardant carpet provided in another embodiment of the present application.

Fig. 3 is a schematic flow chart of a method for manufacturing a flame retardant carpet provided in an embodiment of the present application.

Fig. 4 is a schematic flow chart of a method for manufacturing a flame retardant carpet according to another embodiment of the present application.

Detailed Description

Reference will now be made in detail to embodiments of the present application, examples of which are illustrated in the accompanying drawings, wherein like reference numerals refer to the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are illustrative and are only for the purpose of explaining the present application and are not to be construed as limiting the present application.

The civil aviation carpet is mainly made of wool, and the wool surface layer is subjected to flame retardant treatment so as to meet the flame retardant performance requirements of standards such as CCAR25.853/CCAR23.853/CTSO-2C601 in the civil aviation field. However, the existing carpet for civil aviation is a simple plane model, cannot meet the structural design requirements (such as a molded surface, different thicknesses in different regions, a boss structure, stiffness, support and the like) of the air-ground amphibious manned vehicle, and cannot meet the development requirements of the air-ground amphibious manned vehicle on properties of breaking strength, breaking elongation, high and low temperature resistance, cold and hot alternation resistance, wear resistance and the like.

The structure design can be carried out in land vehicles such as automobile carpets, but the flame retardant property can not meet the vertical combustion requirement in the aviation field. The automobile carpet flame-retardant test meets the requirements of GB8410, wherein a horizontal combustion test mode is adopted, the combustion rate is required to be lower than 100mm/min, a civil aviation carpet adopts a vertical combustion test mode, after 12 seconds of vertical combustion, the flame needs to be self-extinguished within 15 seconds, the scorching length is less than or equal to 203mm, and the drop extinguishing time is less than or equal to 5 seconds. In addition, the civil aviation carpet carries out stricter limit values on smoke density and toxic gas content in the combustion process, wherein the smoke density requires that the maximum smoke density Ds value is not more than 200 after 4min, CO released by toxic gas is not more than 3500 multiplied by 10^-6，HCN≤150×10^-6，HF≤100×10^-6，HCL≤150×10^-6，SO₂≤100×10^-6，NO_X≤100×10^-6。

Specifically, the existing automobile carpet material is subjected to 12s vertical combustion test according to the standards of CCAR25.853/CCAR23.853/CTSO-2C601 and the like in the civil aviation field, and test results show that the carpet has the advantages of long burning time of more than 120s, burning length of more than 305mm and far flame retardant property which can not meet the requirements of the civil aviation field. In addition, in the vertical burning test, when the test sample is thick, it is preferable to start ignition from the outer surface of the test sample, and when the material of the outer surface is poor in flame retardancy, the char length is also significantly longer, and therefore, the flame retardancy of the carpet skin is particularly important.

The conventional carpet for civil use can not be structurally designed, meanwhile, the performances of breaking strength, elongation at break, high and low temperature resistance, cold and hot alternation resistance, wear resistance, sound absorption and sound insulation and the like are far lower than the automobile requirements, and meanwhile, the VOC (Volatile Organic Compounds), smell, atomization and the like can not meet the technical requirements of automobile interior air quality (the requirement that formaldehyde is less than or equal to 200 mu g/m)³Acetaldehyde is less than or equal to 150 mu g/m³Acrolein is less than or equal to 30 mu g/m³Benzene is less than or equal to 50 mu g/m³Toluene is less than or equal to 250 mu g/m³Ethylbenzene is less than or equal to 100 mu g/m³Xylene is less than or equal to 200 mu g/m³Styrene is less than or equal to 100 mu g/m³Normal temperature 23 ℃ odor intensityLess than or equal to 3 grades, less than or equal to 3 grades in the odor intensity of the humidifying environment at 40 ℃, less than or equal to 3.5 grades in the odor intensity at 80 ℃ and less than or equal to 2mg in the atomization value).

The design of the carpet of the air-ground amphibious manned aircraft needs to meet the design and use requirements under two working conditions of flight and land, indexes such as flame retardance, smoke density, toxicity and other releases need to be executed according to civil aviation system regulations, the strict structural design of the automobile carpet needs to be met, performance indexes such as stretching, environment resistance and wear resistance need to be met, and various regulations in the automobile field, such as forbidden material regulations, need to be met at the same time.

In addition, the conventional flame retardant technology comprises a halogen-containing flame retardant system containing bromine, chlorine and the like, a phosphorus-containing flame retardant system containing phosphorus elements, a nitrogen-containing flame retardant system containing triazine structures and the like, and an inorganic flame retardant system containing aluminum hydroxide, magnesium hydroxide and the like, and the technical process comprises ways of copolymerization, blending, flame retardant post-treatment and the like. Among them, the halogen flame retardant system has excellent flame retardant effect, but polybrominated biphenyls and polybrominated diphenyl ethers are definitely forbidden in the national automobile regulation GB 30512, while the halogen flame retardant system can release a large amount of toxic and corrosive gas during combustion, and part of halogen compounds also have carcinogenicity, mutation-causing type, long-term pollution and the like, so the halogen-containing flame retardant is gradually eliminated by the market at present. The inorganic flame retardant has the problems of uneven dispersion in the PET fibers, influence on the molding and strength of the protofilament fibers and the like.

In view of the above, through research, the inventor provides a flame retardant carpet and a method for manufacturing the flame retardant carpet, wherein a napping surface layer and a substrate layer both comprise a flame retardant PET fiber material and a low-melting-point PET fiber material, the flame retardant PET fiber material can improve flame retardancy, the low-melting-point PET fiber material plays a role in molding, and the flame retardant PET fiber material and a flame retardant bottom layer both adopt phosphorus flame retardance, so that the flame retardant carpet can not only meet the flame retardant requirement of an aviation carpet, but also meet the molding requirement, and is suitable for an air-ground amphibious manned aircraft.

In order to make the technical solutions better understood by those skilled in the art, the technical solutions in the embodiments of the present application will be clearly and completely described below with reference to the drawings in the embodiments of the present application. It is to be understood that the embodiments described are only a few embodiments of the present application 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 application.

Referring to fig. 1, an embodiment of the present application provides a flame retardant carpet 100, including a raised surface layer 110, a sound insulation adhesive layer 130, a substrate layer 150, and a flame retardant bottom layer 170, which are sequentially stacked, where the raised surface layer 110 and the substrate layer 150 both include a flame retardant PET fiber material and a low melting point PET fiber material, and the flame retardant PET fiber material and the flame retardant bottom layer 170 both adopt a phosphorus flame retardant.

The embodiment of the application provides fire-retardant carpet 100, nap top layer 110 can satisfy the needle-punched nap process requirement of the air-ground amphibious manned aircraft, nap top layer 110 and substrate layer 150 all include fire-retardant PET fiber material and low-melting point PET fiber material, fire resistance can be improved to fire-retardant PET fiber material, low-melting point PET fiber material plays the shaping effect, guarantee fire-retardant carpet 100's machinability, be convenient for produce in a large number, and fire-retardant PET fiber material and fire-retardant bottom 170 all adopt phosphorus system fire-retardant, satisfy the relevant legislation requirement under two kinds of operating modes of flight and land, finally make fire-retardant carpet 100 not only can satisfy the fire-retardant requirement of aviation carpet, also can satisfy the shaping demand, thereby can be applicable to the air-ground manned aircraft of amphibious.

In this embodiment, the flame-retardant PET fiber material and the flame-retardant bottom layer 170 may be made of phosphorus-based co-flame retardant, or phosphorus-nitrogen-based co-flame retardant. The flame-retardant modes belong to permanent flame retardance, the flame-retardant effect cannot be reduced along with the use, cleaning and other factors of carpets, substances forbidden and limited in regulations are not added into the phosphorus flame retardant, and the flame-retardant fibers meet the regulation requirements of ELV (vehicle scrapping instruction), European Union REACH (chemical registration, evaluation, authorization and limitation), European Union POPs (persistent organic pollutant recasting regulations) and the like. The copolymerization modified flame-retardant PET fiber material has less addition of small molecular flame retardant, and indexes such as VOC, odor property, atomization and the like are better than other flame-retardant modes.

Specifically, the phosphorus-based flame retardant can be added into the fiber raw material by a physical or chemical method, so that the phosphorus-based flame retardant is uniformly distributed in the fiber and is tightly combined with the fiber. For example, through copolymerization flame-retardant modification, flame-retardant elements participate in the polymerization process of fiber polymers, so that the flame retardant is combined into macromolecular chains of the polymers to achieve a long-term flame-retardant result; or, the flame retardant is added into the spinning melt or the solution to be spun into the flame-retardant fiber through blending flame-retardant modification, and the flame retardance and the durability of the flame-retardant fiber are far superior to those of the flame-retardant PET fiber subjected to post-treatment such as dipping, coating and the like.

Of course, the flame retardant PET fiber material and the flame retardant bottom layer 170 are not limited to a single phosphorus-based flame retardant. In other embodiments, the flame retardant PET fiber material and the flame retardant bottom layer 170 can also be a synergistic flame retardant combination of phosphorus flame retardant and nitrogen flame retardant, or a combination of phosphorus flame retardant, nitrogen flame retardant and inorganic hydroxide flame retardant.

In some embodiments, the low-melting-point PET fiber materials in the raised surface layer 110 and the substrate layer 150 may also be partially or completely low-melting-point flame-retardant PET fibers with phosphorus flame retardant, so as to further improve the flame retardant effect of the flame-retardant carpet 100.

For example, if the low-melting-point PET fiber material portion is low-melting-point flame-retardant PET fiber, the raised surface layer 110 includes flame-retardant PET fiber material, low-melting-point PET fiber material, and low-melting-point flame-retardant PET fiber material, and the substrate layer 150 includes flame-retardant PET fiber material, low-melting-point PET fiber material, and low-melting-point flame-retardant PET fiber material. Or, the low-melting-point PET fiber materials are all low-melting-point flame-retardant PET fibers, the raised surface layer 110 may only include the flame-retardant PET fiber material and the low-melting-point flame-retardant PET fiber material, and the substrate layer 150 may only include the flame-retardant PET fiber material and the low-melting-point flame-retardant PET fiber material.

In some embodiments, the phosphorus content of the flame retardant PET fiber material in the raised skin layer 110 and the substrate layer 150 is 0.8% to 1% by mass. The flame-retardant PET fiber material solves the problems that the flame-retardant PET fiber material cannot meet the flame-retardant requirement of an aircraft carpet when the phosphorus content in the flame-retardant PET fiber material is low, and the flame-retardant PET fiber material has too high phosphorus content, thereby bringing great difficulty and challenge to spinning, molding and the like of fibers, so that the flame-retardant PET fiber material can meet the flame-retardant requirement of civil aviation, ensure the processability of the fibers and realize mass production. Illustratively, the mass percentage of the phosphorus element in the flame-retardant PET fiber material may be equal to 0.8%, 0.9%, 0.95%, or 1%, and so on.

In this embodiment, the mass percentage of the phosphorus element in the flame retardant PET fiber material in the raised surface layer 110 and the substrate layer 150 may be further preferably 0.85% to 0.95% to optimize the flame retardancy and processability of the flame retardant PET fiber material.

In some embodiments, the limiting oxygen index of the flame retardant PET fiber material in the raised skin layer 110 and substrate layer 150 is greater than 31. The limiting oxygen index refers to the volume fraction concentration of oxygen in the oxygen and nitrogen mixed gas when just supporting the combustion of the polymer, and the larger the limiting oxygen index is, the flame-retardant material is indicated. The limit oxygen index is larger than 31, which indicates that the flame-retardant PET fiber material belongs to a flame-retardant material and meets the flame-retardant requirement of civil aviation. Illustratively, the limiting oxygen index of the flame retardant PET fiber material may be equal to 32, 34, 35, or 36.

In some embodiments, the low melting point PET fiber material in the pile skin layer 110 and the substrate layer 150 has a melting point of 115 ℃ to 130 ℃. The melting point of the flame-retardant PET fiber material is higher than that of the low-melting-point PET fiber material, and in the process of processing and forming, the low-melting-point PET fiber material can be melted at the temperature lower than that of the flame-retardant PET fiber material, so that the flame-retardant PET fiber materials are bonded with each other, and the forming effect is achieved. Illustratively, the melting point of the low-melting PET fiber material may be 115 ℃, 120 ℃, 126 ℃ or 130 ℃, and so on.

In some embodiments, the substrate layer 150 mainly plays a role in supporting and molding the flame retardant carpet 100, and through the compression molding process, the substrate layer 150 can be molded correspondingly, so as to meet design requirements of carpet profiles, different areas and different thicknesses, and the like. The content of the low melting point PET fiber material in the substrate layer 150 may be greater than the content of the low melting point PET fiber material in the raised surface layer 110, so that the substrate layer 150 has better formability.

Further, the fiber fineness of the flame-retardant PET fiber material of the substrate layer 150 is greater than that of the flame-retardant PET fiber material of the raised surface layer 110, so that the strength requirement of the forming process is met, and the tensile fracture is avoided.

In some embodiments, the flame retardant PET fiber material of the raised surface layer 110 is 70-95% by mass, and the low melting point PET fiber material is 5-30% by mass, so that the raised surface layer 110 has a good combination of flame retardancy and moldability. Illustratively, the flame-retardant PET fiber material of the raised surface layer 110 is 70% by mass, and the low-melting PET fiber material is 30% by mass; or, the flame-retardant PET fiber material of the raised surface layer 110 accounts for 80% by mass, and the low-melting-point PET fiber material accounts for 20% by mass; alternatively, the flame-retardant PET fiber material of the raised surface layer 110 may be 95% by mass and the low-melting PET fiber material may be 5% by mass.

In this embodiment, the raised surface layer 110 has a grammage of 300g/m²-600g/m². Illustratively, the grammage of the raised skin layer 110 may be 300g/m²、500g/m²Or 600g/m². Further, the grammage of the raised skin layer 110 may preferably be 400g/m²-550g/m²To ensure the raising effect and the comprehensive performance.

In other implementations, the raised skin layer 110 determines the flame retardancy of the carpet, taking into account that the carpet's formability is primarily determined by the substrate layer 150. The mass ratio of the flame-retardant PET fiber material in the napping surface layer 110 can be 85-95%, and the mass ratio of the low-melting-point PET fiber material is 5-15%, so that the flame retardance of the napping surface layer 110 is improved by improving the mass ratio of the flame-retardant PET fiber material, and a certain forming effect is kept.

In some embodiments, the flame retardant PET fiber material of raised skin layer 110 has a fiber denier of 4D to 8D and a fiber length of 51mm to 90 mm; the low-melting-point PET fiber material of the raised surface layer 110 has a fiber fineness of 4D and a fiber length of 51mm to 90 mm.

It should be noted that when the grammage of the raised surface layer 110 is fixed, the fineness of the flame-retardant PET fiber material is higher, the fiber bundles are more sparse after needling and have too high fineness, and the raised surface layer 110 is sparse due to stretching in the forming process, so that the raised surface layer 110 is poor in hand feeling and appearance, and even poor in light transmission and sound absorption; when the titer of the flame-retardant fiber is too low, the flame-retardant PET fiber material is soft, and meanwhile, the needling raising effect is poor; for example, when the surface layer is needle-punched and napped with a flame-retardant PET fiber material having a fiber limit equal to 3D and a fiber length equal to 51mm, the napped height is only about 2mm, and the needle-punched napped effect, the hand feeling, and the appearance effect are poor, and the carpet design requirements cannot be met. In the embodiment, the raised surface layer 110 is made by mixing the flame-retardant PET fiber material and the low-melting-point PET fiber material in the above range, so that the flame-retardant carpet 100 can meet the carpet design and use requirements of the air-ground amphibious manned aircraft.

Illustratively, the fiber fineness of the flame retardant PET fiber material of the raised surface layer 110 may be 4D, 6D, 8D, or the like, and the fiber length may be equal to 51mm, 64mm, 76mm, 90mm, or the like. The low melting point PET fiber material of the raised skin layer 110 may have a fiber length of 51mm, 64mm, 76mm, or 90mm, etc., and the raised skin layer 110 may have a raised height of 3mm, 4mm, 4.5mm, or 5mm, etc.

In the embodiment, the pile height of the pile surface layer 110 is 3mm-5mm, the pile effect, the hand feeling and the appearance are good, and the design requirement of the carpet can be met. Illustratively, the pile height of the raised surface layer 110 may be 3mm, 4mm, or 5mm, etc.

In some embodiments, the soundproof adhesive layer 130 includes a first PE (polyethylene) film layer, a PA (Polyamide) film layer, and a second PE film layer, which are sequentially stacked. The PA film layer has certain flame retardance, the first PE film layer and the second PE film layer are melted during high-temperature forming, the effect of connecting the napped surface layer 110 and the base material layer 150 is achieved, and meanwhile, a good sound insulation effect is achieved; on the other hand, the soundproof adhesive layer 130 is inevitably punctured by the flame-retardant base layer 170 when the flame-retardant base layer 170 is compression-molded.

In this embodiment, the soundproof adhesive layer 130 may be bonded to the pile surface layer 110 through a hot pressing process. The thickness of the first PE film layer may be equal to the thickness of the second PE film layer, and the thickness of the PA film layer may be greater than the first PE film layer and the second PE film layer to improve the flame retardancy of the soundproof adhesive layer 130. The grammage of the soundproof adhesive layer 130 is 100g/m²-200g/m². Illustratively, the grammage of the sound-damping adhesive layer 130 may be equal to 100g/m²、150g/m²、170g/m²Or 200g/m²And the like.

In other embodiments, the sound-insulating adhesive layer 130 may also be a single layer of PE film, which may be made by a film coating process or a powder spreading process.

In some embodiments, the mass ratio of the flame-retardant PET fiber material in the substrate layer 150 is 60% to 80%, and the mass ratio of the low-melting-point PET fiber material is 20% to 30%, so that the substrate layer 150 has a good molding effect, and the overall flame-retardant effect of the flame-retardant carpet 100 can also be ensured. The low melting point PET fiber material is contained in the base material layer 150 in an amount greater than that of the raised skin layer 110 to provide more shaping.

In this embodiment, the substrate layer 150 may further include a low-melting-point flame-retardant PET fiber material adopting a phosphorus flame retardant, and the mass ratio of the low-melting-point flame-retardant PET fiber material may be 0% to 30%. Illustratively, the substrate layer 150 comprises a flame-retardant PET fiber material, a low-melting-point PET fiber material and a low-melting-point flame-retardant PET fiber material adopting a phosphorus flame retardant, the mass percentage of the flame-retardant PET fiber material in the substrate layer 150 is 60%, the mass percentage of the low-melting-point PET fiber material is 30%, and the mass percentage of the low-melting-point flame-retardant PET fiber material is 10%; or, the mass percentage of the flame-retardant PET fiber material in the substrate layer 150 is 70%, and the mass percentage of the low-melting-point PET fiber material is 30%; alternatively, the mass percentage of the flame-retardant PET fiber material in the base material layer 150 is 80%, and the mass percentage of the low-melting-point PET fiber material is 20%. The thickness of the substrate layer 150 may be equal to 3mm, 4mm, 4.5mm, or 5mm, etc.

In some embodiments, the grammage of the substrate layer 150 is 400g/m²-600g/m²And the thickness of the base material layer 150 is 3mm-5 mm. The fiber fineness of the flame-retardant PET fiber material in the base material layer 150 is 8D-15D, and the fiber length is 51mm-90 mm. The fiber fineness of the low-melting-point PET fiber material in the base material layer 150 is 4D, and the fiber length is 51mm-90 mm. Compare in pile top layer 110, the fibre fineness of fire-retardant PET fibrous material in substrate layer 150 is bigger to avoid tensile fracture in forming process, and this embodiment passes through the combination requirement of fibre fineness, fiber length and gram weight, makes substrate layer 150 can satisfy the carpet fire-retardant of air-ground amphibious manned vehicle, stiffness, support, structural design, inhale and inhaleAcoustic and mechanical properties. .

Illustratively, the grammage of the substrate layer 150 may be 400g/m²、500g/m²Or 600g/m²And so on. The thickness of the substrate layer 150 may be equal to 3mm, 4mm, 5mm, or the like. The fiber fineness of the flame-retardant PET fiber material in the base material layer 150 can be equal to 8D, 10D, 14D or 15D and the like, and the fiber length can be equal to 51mm, 64mm, 76mm or 90mm and the like. The fiber length of the low melting point PET fiber material in the substrate layer 150 may be equal to 51mm, 64mm, 76mm, or 90mm, etc.

In some embodiments, the flame retardant bottom layer 170 is a flame retardant foamed PU (Polyurethane) layer. The flame-retardant foamed PU has excellent heat insulation, sound insulation and fire resistance and long service life.

In this example, the density of the flame-retardant foamed PU was 60g/m³. The thickness of the flame-retardant lower layer 170 is 20mm to 30 mm. Illustratively, the thickness of the flame retardant bottom layer 170 may be equal to 20mm, 25mm, 27mm, or 30mm, etc.

Of course, the flame retardant bottom layer 170 is not limited to being made of flame retardant foamed PU material. In other embodiments, the bottom flame retardant layer 170 may be made of equal density cotton, standing cotton, or a mixture of EVA (ethylene vinyl acetate) and PU, which have the same flame retardant effect.

Referring to fig. 2, in some embodiments, the flame retardant carpet 100 further includes a flame retardant latex layer 120, the flame retardant latex layer 120 is stacked between the raised surface layer 110 and the sound insulation adhesive layer 130, and the flame retardant latex layer 120 is flame retardant by using phosphorus. This embodiment adds fire-retardant emulsion layer 120 back between gigging top layer 110 and sound insulation adhesive linkage 130, is equivalent to and carries out the rubber coating in the bottom on gigging top layer 110, can stereotype the fibre on gigging top layer 110, and fixed chemical fibre that can be better improves the wearability simultaneously.

In this embodiment, the flame-retardant latex layer 120 may adopt a phosphorus-based blending flame-retardant or phosphorus-nitrogen-based blending flame-retardant manner, so as to meet the requirements of relevant regulations at home and abroad. The flame-retardant latex layer 120 may be an SBR (styrene butadiene rubber) flame-retardant latex layer or an EVA flame-retardant latex layer. The gram weight of the flame-retardant latex layer 120 is 50g/m²-100g/m². Exemplary, flame retardant latex layer 120The grammage may be equal to 50g/m²、60g/m²、80g/m²Or 100g/m²And the like.

After the flame retardant carpet 100 provided in the embodiment of the present application is molded, the performance specifications are shown in the following table.

Table one: performance specifications for flame retardant carpet 100

The flame-retardant carpet 100 provided by the embodiment of the application can meet the flame-retardant requirement in the field of civil aviation, can realize a permanent flame-retardant effect, and also solves the problem that an aviation carpet can only be molded in a plane and cannot be made into a complex structure; meanwhile, the fiber titer and the matching combination of the flame-retardant PET fiber material and the low-melting-point PET fiber material also meet the design requirements of needling effect, high pile, formability, wear resistance, elongation at break and the like.

Referring to fig. 3, the present application also provides a method for manufacturing a flame retardant carpet, which may specifically include the following steps S110 to S140.

Step S110: the low-melting-point PET fiber material and the flame-retardant PET fiber material adopting the phosphorus flame retardant are mixed and then are needled and napped to form a napped surface layer.

Feeding, opening, mixing, carding and lapping the low-melting-point PET fiber material and the flame-retardant PET fiber material adopting the phosphorus flame retardant according to a set proportion to form a uniform fiber web, and carrying out needle punching and raising through a needle punching process to form a raised surface layer.

Step S120: and a sound insulation bonding layer is attached to the bottom surface of the raised surface layer.

The bottom surface of the napping surface layer is the surface of the napping surface layer facing the ground when the flame-retardant carpet is used. When the sound insulation bonding layer comprises a first PE film layer, a PA film layer and a second PE film layer which are sequentially stacked, the sound insulation bonding layer and the napping surface layer can be bonded through a hot pressing process. When the sound insulation bonding layer is a single-layer PE film, the single-layer PE film can be obtained by film coating on the bottom surface of the raised surface layer.

Step S130: and mixing the low-melting-point PET fiber material with the flame-retardant PET fiber material adopting the phosphorus system to form a base material layer, and compounding the base material layer on the surface of the sound-insulation bonding layer, which is deviated from the napping surface layer.

The low-melting-point PET fiber material and the flame-retardant PET fiber material adopting the phosphorus flame retardant system are mixed according to a set proportion, then are carded and are laid to form an even base material layer, then the base material layer is placed on the surface of the sound insulation bonding layer deviating from the napping surface layer, and the base material layer, the sound insulation bonding layer and the napping surface layer are compounded together through a compression molding process.

Step S140: and providing a flame-retardant bottom layer adopting phosphorus flame retardance, and compounding the flame-retardant bottom layer on the surface of the base material layer, which is far away from the sound-insulation bonding layer.

When fire-retardant bottom is fire-retardant foaming PU layer, can form fire-retardant bottom through injection technology on the surface that the substrate layer deviates from the adhesive linkage that gives sound insulation, rethread compression molding technology with fire-retardant bottom, substrate layer, the adhesive linkage that gives sound insulation and pile surface layer complex together, form fire-retardant carpet.

Referring to fig. 4, in some embodiments, the manufacturing method provided in the embodiments of the present application may specifically include the following steps S210 to S250.

Step S210: the low-melting-point PET fiber material and the flame-retardant PET fiber material adopting the phosphorus flame retardant are mixed and then are needled and napped to form a napped surface layer.

Step S220: and gluing the bottom surface of the raised surface layer to form a phosphorus flame-retardant emulsion layer.

And coating the raw materials of the flame-retardant latex layer on the bottom surface of the raised surface layer, and curing to form the flame-retardant latex layer.

Step S230: and a sound insulation bonding layer is attached to the surface of the flame-retardant latex layer, which is far away from the raised surface layer.

Specifically, when the sound insulation adhesive layer comprises a first PE film layer, a PA film layer and a second PE film layer which are sequentially stacked, the prepared sound insulation adhesive layer, the flame-retardant emulsion layer and the napping surface layer can be pressed through a hot pressing process. When the sound insulation bonding layer is a single-layer PE film, the film can be sprayed on the bottom surface of the flame-retardant emulsion layer to obtain the single-layer PE film.

Step S240: and mixing the low-melting-point PET fiber material with the flame-retardant PET fiber material adopting phosphorus flame retardance to form a base material layer, and compounding the base material layer on the surface of the sound-insulation adhesive layer, which is far away from the flame-retardant emulsion layer.

The low-melting-point PET fiber material and the flame-retardant PET fiber material adopting the phosphorus system are mixed according to a set proportion, then are carded and are laid to form an even base material layer, then the base material layer is stacked on the surface of the sound-insulation bonding layer deviating from the flame-retardant latex layer, and the base material layer, the sound-insulation bonding layer, the flame-retardant latex layer and the napping surface layer are compounded together through a compression molding process.

Step S250: and providing a flame-retardant bottom layer adopting phosphorus flame retardance, and compounding the flame-retardant bottom layer on the surface of the base material layer, which is far away from the sound-insulation bonding layer.

When fire-retardant bottom is fire-retardant foaming PU layer, can form fire-retardant bottom through injection technology on the surface that the substrate layer deviates from the adhesive linkage that gives sound insulation, rethread compression molding process will fire-retardant bottom, substrate layer, adhesive linkage that gives sound insulation, fire-retardant emulsion layer and pile surface layer complex be in the same place, form fire-retardant carpet.

It is clear to those skilled in the art that, for convenience and brevity of description, the detailed structural features of the flame retardant carpet in the above manufacturing method are referred to the related description of the above related embodiments, and are not repeated herein.

The flame retardant carpet and the method of making the flame retardant carpet of the present invention are further described below by way of specific examples. The following examples are, of course, intended to illustrate the invention and are not intended to limit the scope of the invention.

Example one

The embodiment of the application provides a flame-retardant carpet, including pile surface layer, fire-retardant emulsion layer, the adhesive linkage that gives sound insulation, substrate layer and the fire-retardant bottom of range upon range of arranging in proper order.

The napping surface layer contains flame-retardant PET fiber material and low-melting-point fiber PET material, and the gram weight of the napping surface layer is equal to 400g/m². The flame-retardant PET fiber material is characterized in that the fiber number of the flame-retardant PET fiber material is 8D, the fiber length is 76mm, the flame-retardant method adopts a phosphorus copolymerization flame-retardant mode, and the mass percentage of phosphorus element is 0.9%. The low-melting-point PET fiber material has a fiber fineness of 4D and a fiber length of 51 mm. The mass proportion of the flame-retardant PET fiber material in the raised surface layer is 90%, and correspondingly, the mass proportion of the low-melting-point PET fiber material in the raised surface layer is 10%. And mixing the flame-retardant PET fiber material and the low-melting-point PET fiber material, carding, lapping, and finally needling and raising, wherein the height of raised pile after needling and raising is 5 mm.

The flame-retardant latex layer is an SBR flame-retardant latex layer, and the gram weight of the flame-retardant latex layer is 100g/m². The flame-retardant method of the flame-retardant latex layer can adopt a phosphorus-series blending flame-retardant or phosphorus-nitrogen-series blending flame-retardant mode.

The sound insulation adhesive layer comprises a first PE film layer, a PA film layer and a second PE film layer which are arranged in a stacked mode, and the gram weight of the sound insulation adhesive layer is 100g/m²。

The substrate layer comprises a flame-retardant PET fiber material and a low-melting-point PET fiber material, and the gram weight of the substrate layer is 500g/m². The flame-retardant PET fiber material is characterized in that the fiber fineness of the flame-retardant PET fiber material is 12D, the fiber length is 64mm, the flame-retardant method adopts a phosphorus copolymerization flame-retardant mode, and the mass percentage of phosphorus in the flame-retardant PET fiber material is 0.9%. The low-melting-point PET fiber material has a fiber fineness of 4D and a fiber length of 51 mm. The weight proportion of the flame-retardant PET fiber material in the base material layer is 80%, and correspondingly, the weight proportion of the low-melting-point PET fiber material in the base material layer is 20%. The flame-retardant PET fiber material and the low-melting-point PET fiber material are mixed, carded, lapped and compounded.

The flame-retardant bottom layer is made of flame-retardant foamed PU, and the flame-retardant method adopts a phosphorus flame-retardant methodSpecifically, the flame retardant can be phosphorus-based copolymerization flame retardant, phosphorus-based blending flame retardant or phosphorus-nitrogen-based blending flame retardant. The density of the flame-retardant foamed PU body is 60g/m³The thickness of the flame-retardant bottom layer ranges from 20mm to 30 mm.

The method for manufacturing the flame retardant carpet may specifically include the following steps 310 to S350.

Step 310: feeding, opening, mixing, carding, lapping, needling and napping a low-melting-point PET fiber material and a flame-retardant PET fiber material adopting a phosphorus flame retardant according to a set proportion to form a napped surface layer.

Step S320: and coating the SBR flame-retardant latex on the bottom surface of the raised surface layer to form a flame-retardant latex layer.

Step S330: and a sound insulation bonding layer is attached to the surface of the flame-retardant latex layer, which is far away from the raised surface layer.

Step S340: mixing a low-melting-point PET fiber material and a flame-retardant PET fiber material adopting a phosphorus system flame retardant according to a set proportion, carding and lapping to form an even substrate layer, and then compounding the substrate layer on the surface of the sound insulation bonding layer departing from the flame-retardant emulsion layer through a compression molding process.

Step S350: injecting the flame-retardant foaming PU on the surface of the base material layer deviating from the sound-insulation bonding layer to form a flame-retardant bottom layer, and compounding the flame-retardant bottom layer, the base material layer, the sound-insulation bonding layer, the flame-retardant emulsion layer and the napping surface layer together by a compression molding process to form the flame-retardant carpet.

Example two

The embodiment of the application provides a fire-retardant carpet, including pile top layer, the adhesive linkage that gives sound insulation, substrate layer and the fire-retardant bottom of range upon range of arranging in proper order.

The napping surface layer contains flame-retardant PET fiber material and low-melting-point PET fiber material, and the gram weight of the napping surface layer is 400g/m². The flame-retardant PET fiber material is characterized in that the fiber number of the flame-retardant PET fiber material is 8D, the fiber length is 76mm, the flame-retardant method adopts a phosphorus copolymerization flame-retardant mode, and the mass percentage of phosphorus element is 0.9%. The low-melting-point PET fiber material has a fiber fineness of 4D and a fiber length of 51 mm. The weight ratio of the flame-retardant PET fiber material in the raised surface layer is 90%, and correspondingly, the weight of the low-melting-point PET fiber material in the raised surface layerThe amount of the nano-particles accounts for 10 percent. And (3) mixing the flame-retardant PET fiber material and the low-melting-point PET fiber material, carding, lapping, and finally needling and napping, wherein the napping height after needling and napping is 5 mm.

The sound insulation adhesive layer comprises a first PE film layer, a PA film layer and a second PE film layer which are arranged in a stacked mode, and the gram weight of the sound insulation adhesive layer is 150g/m²。

The substrate layer comprises a flame-retardant PET fiber material and a low-melting-point PET fiber material, and the gram weight of the substrate layer is 500g/m². The flame-retardant PET fiber material is characterized in that the fiber number range of the flame-retardant PET fiber material is 12D, the fiber length is 64mm, the flame-retardant method adopts a phosphorus copolymerization flame-retardant mode, and the mass percentage of phosphorus element is 0.9%. The low-melting-point PET fiber material has a fiber fineness of 4D and a fiber length of 51 mm. The weight proportion of the flame-retardant PET fiber material in the base material layer is 80%, and correspondingly, the weight proportion of the low-melting-point PET fiber material in the base material layer is 20%. The flame-retardant PET fiber material and the low-melting-point PET fiber material are mixed, carded, lapped and compounded.

The flame-retardant bottom layer is made of flame-retardant foamed PU, and the flame-retardant method adopts a phosphorus flame-retardant mode, and specifically can be phosphorus copolymerization flame-retardant, phosphorus blending flame-retardant or phosphorus-nitrogen blending flame-retardant. The bulk density of the flame-retardant foamed PU is 60g/m³The thickness of the flame-retardant bottom layer ranges from 20mm to 30 mm.

The method for manufacturing the flame retardant carpet may specifically include the following steps 410 to 440.

Step 410: feeding, opening, mixing, carding, lapping, needling and napping a low-melting-point PET fiber material and a flame-retardant PET fiber material adopting a phosphorus flame retardant according to a set proportion to form a napped surface layer.

Step S420: and a sound insulation bonding layer is attached to the bottom surface of the raised surface layer.

Step S430: mixing a low-melting-point PET fiber material and a flame-retardant PET fiber material adopting a phosphorus flame retardant system according to a set proportion, carding and lapping to form a substrate layer, and compounding the substrate layer on the surface of the sound insulation bonding layer, which is far away from the napping surface layer, through a compression molding process.

Step S440: injecting the flame-retardant foaming PU on the surface of the base material layer deviating from the sound-insulation bonding layer to form a flame-retardant bottom layer, and compounding the flame-retardant bottom layer, the base material layer, the sound-insulation bonding layer, the flame-retardant emulsion layer and the napping surface layer together by a compression molding process to form the flame-retardant carpet.

EXAMPLE III

The third embodiment of the application provides a fire-retardant carpet, including pile surface layer, fire-retardant emulsion layer, the adhesive linkage that gives sound insulation, substrate layer and the fire-retardant bottom of range upon range of arranging in proper order.

The napping surface layer contains flame-retardant PET fiber material and low-melting-point PET fiber material, and the gram weight of the napping surface layer is 350g/m². The flame-retardant PET fiber material is characterized in that the fiber number of the flame-retardant PET fiber material is 6D, the fiber length is 64mm, the flame-retardant method adopts a phosphorus copolymerization flame-retardant mode, and the mass percentage of phosphorus in the flame-retardant PET fiber material is 0.9%. The fineness of the low-melting-point PET fiber material is 4D, and the fiber length is 51 mm. The weight proportion of the flame-retardant PET fiber material in the raised surface layer is 90%, and correspondingly, the weight proportion of the low-melting-point PET fiber material in the raised surface layer is 10%. And (3) mixing the flame-retardant PET fiber material and the low-melting-point PET fiber material, carding, lapping, and finally needling and napping, wherein the napping height after needling and napping is 4 mm.

The flame-retardant latex layer is an SBR flame-retardant latex layer, and the gram weight of the flame-retardant latex layer is 50g/m²The flame-retardant method adopts a phosphorus-based blending flame-retardant or phosphorus-nitrogen-based blending flame-retardant mode.

The base material layer comprises a flame-retardant PET fiber material and a low-melting-point PET fiber material, and the gram weight of the material of the base material layer is 400g/m². The fiber fineness of the flame-retardant PET fiber material is 15D, the fiber length is 64mm, the flame-retardant method adopts a phosphorus copolymerization flame-retardant mode, and the mass percentage of phosphorus is 0.9%. The fineness of the low-melting-point PET fiber material is 4D, and the fiber length is 51 mm. The weight proportion of the flame-retardant PET fiber material in the base material layer is 70%, and correspondingly, the weight proportion of the low-melting-point PET fiber material in the base material layer is 30%. The flame-retardant PET fiber material and the low-melting-point PET fiber material are mixed, carded, lapped and compounded.

The flame-retardant bottom layer is made of flame-retardant foamed PU, the flame-retardant method adopts phosphorus flame retardant, such as phosphorus copolymerization flame retardant, phosphorus blending flame retardant or phosphorus-nitrogen blending flame retardant, and the bulk density of the flame-retardant foamed PU is 60g/m³The thickness of the flame-retardant bottom layer is between 20mm and 30 mm.

The method for manufacturing the flame retardant carpet may specifically include the following steps 510 to S550.

Step 510: feeding, opening, mixing, carding, lapping, needling and napping a low-melting-point PET fiber material and a flame-retardant PET fiber material adopting a phosphorus flame retardant according to a set proportion to form a napped surface layer.

Step S520: and coating the SBR flame-retardant latex on the bottom surface of the raised surface layer to form a flame-retardant latex layer.

Step S530: and a sound insulation bonding layer is attached to the surface of the flame-retardant latex layer, which is far away from the raised surface layer.

Step S540: mixing a low-melting-point PET fiber material and a flame-retardant PET fiber material adopting a phosphorus flame retardant system according to a set proportion, carding and lapping to form an even substrate layer, and compounding the substrate layer on the surface of the sound insulation bonding layer departing from the flame-retardant emulsion layer through a compression molding process.

Step S550: injecting the flame-retardant foaming PU on the surface of the base material layer deviating from the sound-insulation bonding layer to form a flame-retardant bottom layer, and compounding the flame-retardant bottom layer, the base material layer, the sound-insulation bonding layer, the flame-retardant emulsion layer and the napping surface layer together by a compression molding process to form the flame-retardant carpet.

Example four

The fourth embodiment of the application provides a fire-retardant carpet, including pile top layer, the adhesive linkage that gives sound insulation, substrate layer and the fire-retardant bottom of range upon range of arranging in proper order.

The napping surface layer contains flame-retardant PET fiber material and low-melting-point PET fiber material, and the gram weight of the napping surface layer is 350g/m². The flame-retardant PET fiber material is characterized in that the fiber number of the flame-retardant PET fiber material is 6D, the fiber length is 64mm, the flame-retardant method adopts a phosphorus copolymerization flame-retardant mode, and the mass percentage of phosphorus in the flame-retardant PET fiber material is 0.9%. The low-melting-point PET fiber material has a fiber fineness of 4D and a fiber length of 51 mm. Resistance deviceThe weight proportion of the flame-retardant PET fiber material in the raised surface layer was 90%, and correspondingly, the weight proportion of the low-melting PET fiber material in the raised surface layer was 10%. And (3) mixing the flame-retardant PET fiber material and the low-melting-point PET fiber material, carding, lapping, and finally needling and napping, wherein the napping height after needling and napping is 4 mm.

The substrate layer comprises a flame-retardant PET fiber material and a low-melting-point PET fiber material, and the gram weight of the substrate layer is 400g/m². The flame-retardant PET fiber material is characterized in that the fiber number range of the flame-retardant PET fiber material is 15D, the fiber length is 64mm, the flame-retardant method adopts a phosphorus copolymerization flame-retardant mode, and the mass percentage of phosphorus is 0.9%. The low-melting-point PET fiber material has a fiber fineness of 4D and a fiber length of 51 mm. And part of the low-melting-point PET fiber material is also subjected to phosphorus flame retardant treatment to form the low-melting-point flame retardant PET fiber material. The weight ratio of the flame-retardant PET fiber material in the base material layer is 70%, the weight ratio of the low-melting-point flame-retardant PET fiber material in the base material layer is 15%, and the weight ratio of the low-melting-point PET fiber material in the base material layer is 15%. And the flame-retardant PET fiber material, the low-melting-point flame-retardant PET fiber material and the low-melting-point PET fiber material are mixed, carded, lapped and compounded.

The flame-retardant bottom layer is made of flame-retardant foamed PU, and the flame-retardant method adopts a phosphorus flame-retardant mode, and specifically can be phosphorus copolymerization flame-retardant, phosphorus blending flame-retardant or phosphorus-nitrogen blending flame-retardant. The bulk density of the flame-retardant foamed PU is 60g/m³And the thickness of the flame-retardant bottom layer ranges from 20mm to 30 mm.

The method for manufacturing the flame retardant carpet may specifically include the following steps 610 to S640.

Step 610: feeding, opening, mixing, carding, lapping, needling and napping a low-melting-point PET fiber material and a flame-retardant PET fiber material adopting a phosphorus flame retardant according to a set proportion to form a napped surface layer.

Step S620: and a sound insulation bonding layer is attached to the bottom surface of the raised surface layer.

Step S630: mixing a low-melting-point PET fiber material, a phosphorus-based flame-retardant low-melting-point flame-retardant PET fiber material and a phosphorus-based flame-retardant PET fiber material according to a set proportion, carding and lapping to form a base material layer, and compounding the base material layer on the surface of the sound-insulation bonding layer, which is far away from the napping surface layer, through a compression molding process.

Step S640: inject fire-retardant foaming PU and form fire-retardant bottom on the surface that the substrate layer deviates from the adhesive linkage that gives sound insulation, rethread compression molding process will fire-retardant bottom, substrate layer, adhesive linkage that gives sound insulation, fire-retardant emulsion layer and pile top layer complex be in the same place, form fire-retardant carpet.

EXAMPLE five

The fifth embodiment of the application provides a flame-retardant carpet, including pile top layer, the adhesive linkage that gives sound insulation, substrate layer and the fire-retardant bottom of range upon range of arranging in proper order.

The napping surface layer contains flame-retardant PET fiber material and low-melting-point PET fiber material, and the gram weight of the napping surface layer is 350g/m². The fiber fineness of the flame-retardant PET fiber material is 6D, the fiber length is 64mm, the flame-retardant method adopts a phosphorus copolymerization flame-retardant mode, and the mass percentage of phosphorus in the flame-retardant PET fiber material is 0.9%. The low-melting-point PET fiber material has a fiber fineness of 4D and a fiber length of 51 mm. The weight proportion of the flame-retardant PET fiber material in the raised surface layer is 90%, and correspondingly, the weight proportion of the low-melting-point PET fiber material in the raised surface layer is 10%. And (3) mixing the flame-retardant PET fiber material and the low-melting-point PET fiber material, carding, lapping, and finally needling and napping, wherein the napping height after needling and napping is 4 mm.

The substrate layer comprises a flame-retardant PET fiber material and a low-melting-point PET fiber material, and the gram weight of the substrate layer is 400g/m². The flame-retardant PET fiber material is characterized in that the fiber number range of the flame-retardant PET fiber material is 15D, the fiber length is 64mm, the flame-retardant method adopts a phosphorus copolymerization flame-retardant mode, and the mass percentage of phosphorus is 0.9%. The low-melting-point PET fiber material has a fiber fineness of 4D and a fiber length of 51 mm. The low-melting-point PET fiber material is also subjected to phosphorus flame retardant treatment to form low-melting-point flame retardantA PET fiber material. The weight proportion of the flame-retardant PET fiber material in the base material layer is 70%, and the weight proportion of the low-melting-point flame-retardant PET fiber material in the base material layer is 30%. The flame-retardant PET fiber material and the low-melting-point flame-retardant PET fiber material are mixed, carded, lapped and compounded.

The method for manufacturing the flame retardant carpet may specifically include the following steps 710 to S740.

Step 710: feeding, opening, mixing, carding, lapping, needling and napping a low-melting-point PET fiber material and a flame-retardant PET fiber material adopting a phosphorus flame retardant according to a set proportion to form a napped surface layer.

Step S720: and a sound insulation adhesive layer is attached to the bottom surface of the raised surface layer.

Step S730: mixing the phosphorus flame-retardant low-melting-point flame-retardant PET fiber material and the phosphorus flame-retardant PET fiber material according to a set proportion, carding and lapping to form a substrate layer, and compounding the substrate layer on the surface of the sound-insulation bonding layer, which is far away from the napping surface layer, through a compression molding process.

Step S740: injecting the flame-retardant foaming PU on the surface of the base material layer deviating from the sound-insulation bonding layer to form a flame-retardant bottom layer, and compounding the flame-retardant bottom layer, the base material layer, the sound-insulation bonding layer, the flame-retardant emulsion layer and the napping surface layer together by a compression molding process to form the flame-retardant carpet.

EXAMPLE six

The embodiment of the application provides an inflaming retarding carpet, including pile-up top layer, fire-retardant emulsion layer, the adhesive linkage that gives sound insulation, substrate layer and the fire-retardant bottom of range upon range of arranging in proper order.

The napping surface layer contains flame-retardant PET fiber material and low-melting-point fiber PET material, and the gram weight of the napping surface layer is equal to 500g/m². Wherein the fiber fineness of the flame-retardant PET fiber material is 6D, the fiber length is 64mm, and the flame-retardant method adopts a phosphorus systemThe copolymerization flame-retardant mode is that the mass percent of the phosphorus element is 0.9 percent. The low-melting-point PET fiber material has a fiber fineness of 4D and a fiber length of 51 mm. The mass proportion of the flame-retardant PET fiber material in the napped surface layer is 74%, and correspondingly, the mass proportion of the low-melting-point PET fiber material in the napped surface layer is 26%. And mixing the flame-retardant PET fiber material and the low-melting-point PET fiber material, carding, lapping, and finally needling and napping, wherein the napping height after needling and napping is 4 mm.

The flame-retardant latex layer is EVA flame-retardant latex layer, and the gram weight of the flame-retardant latex layer is 100g/m². The flame-retardant method of the flame-retardant emulsion layer adopts a phosphorus-nitrogen system blending flame-retardant mode. The sound insulation adhesive layer comprises a first PE film layer, a PA film layer and a second PE film layer which are arranged in a stacked mode, and the gram weight of the sound insulation adhesive layer is 100g/m²。

The substrate layer comprises a flame-retardant PET fiber material and a low-melting-point PET fiber material, and the gram weight of the substrate layer is 500g/m². The flame-retardant PET fiber material is characterized in that the fiber fineness of the flame-retardant PET fiber material is 12D, the fiber length is 64mm, the flame-retardant method adopts a phosphorus copolymerization flame-retardant mode, and the mass percentage of phosphorus in the flame-retardant PET fiber material is 0.85%. The low-melting-point PET fiber material has a fiber fineness of 4D and a fiber length of 51 mm. The weight proportion of the flame-retardant PET fiber material in the base material layer is 65%, and correspondingly, the weight proportion of the low-melting-point PET fiber material in the base material layer is 35%. The flame-retardant PET fiber material and the low-melting-point PET fiber material are mixed, carded, lapped and compounded.

The flame-retardant bottom layer is made of flame-retardant foamed PU, and the flame-retardant method adopts a phosphorus flame-retardant mode, and specifically can be phosphorus copolymerization flame-retardant, phosphorus blending flame-retardant or phosphorus-nitrogen blending flame-retardant. The density of the flame-retardant foamed PU body is 60g/m³The thickness of the flame-retardant bottom layer was 25 mm.

The percentage of the low-melting-point PET fiber materials in the napping surface layer and the base material layer is increased, the mass percentage of phosphorus elements in the flame-retardant PET fiber materials is reduced, and the fiber fineness, the fiber length, the gram weight and the napping height are limited, so that the formability of the flame-retardant carpet is improved.

EXAMPLE seven

The seventh embodiment of the application provides a fire-retardant carpet, including pile surface layer, fire-retardant emulsion layer, the adhesive linkage that gives sound insulation, substrate layer and the fire-retardant bottom of range upon range of arranging in proper order.

The napping surface layer contains flame-retardant PET fiber material and low-melting-point PET fiber material, and the gram weight of the napping surface layer is equal to 450g/m². The flame-retardant PET fiber material is characterized in that the fiber number of the flame-retardant PET fiber material is 5D, the fiber length is 76mm, the flame-retardant method adopts a phosphorus copolymerization flame-retardant mode, and the mass percentage of phosphorus is 0.98%. The fiber fineness of the low-melting-point PET fiber material is 4D, and the fiber length is 90 mm. The mass proportion of the flame-retardant PET fiber material in the napped surface layer is 93%, and correspondingly, the mass proportion of the low-melting-point PET fiber material in the napped surface layer is 7%. And mixing the flame-retardant PET fiber material and the low-melting-point PET fiber material, carding, lapping, and finally needling and napping, wherein the napping height after needling and napping is 4 mm.

The substrate layer comprises a flame-retardant PET fiber material and a low-melting-point PET fiber material, and the gram weight of the substrate layer is 500g/m². The flame-retardant PET fiber material is characterized in that the fiber number of the flame-retardant PET fiber material is 12D, the fiber length is 64mm, the flame-retardant method adopts a phosphorus copolymerization flame-retardant mode, and the mass percentage of phosphorus in the flame-retardant PET fiber material is 0.97%. The low-melting-point PET fiber material has a fiber fineness of 4D and a fiber length of 51 mm. The weight proportion of the flame-retardant PET fiber material in the base material layer is 80%, and correspondingly, the weight proportion of the low-melting-point PET fiber material in the base material layer is 20%. The flame-retardant PET fiber material and the low-melting-point PET fiber material are mixed, carded, lapped and compounded.

The seventh embodiment of the invention improves the mass ratio of the flame-retardant PET fiber material in the raised surface layer and the base material layer, improves the mass percentage of phosphorus in the flame-retardant PET fiber material, and limits the fiber fineness, the fiber length, the gram weight and the pile height to improve the flame retardance of the flame-retardant carpet.

In the first to seventh embodiments, the fourth embodiment has the best overall effects of flame retardant effect, smoke density and toxic gas amount, needle raising effect, breaking strength and elongation, weight, formability, VOC, odor, cost, and the like.

Although the present application has been described with reference to a preferred embodiment, it should be understood that various changes, substitutions and alterations can be made herein without departing from the spirit and scope of the invention as defined by the appended claims.

Claims

1. The utility model provides a flame-retardant carpet, its characterized in that, is including the pile top layer, the adhesive linkage that gives sound insulation, substrate layer and the fire-retardant bottom of range upon range of arranging in proper order, wherein, the pile top layer with the substrate layer all includes fire-retardant PET fiber material and low melting point PET fiber material, fire-retardant PET fiber material with fire-retardant bottom all adopts phosphorus to be fire-retardant.

2. The flame retardant carpet of claim 1, wherein the flame retardant PET fiber material contains 0.8-1% of phosphorus by mass.

3. The flame retardant carpet of claim 1 wherein the flame retardant PET fiber material has a limiting oxygen index of greater than 31.

4. The flame retardant carpet of claim 1 wherein the low melting point PET fiber material has a melting point of 115 ℃ to 130 ℃.

5. The flame retardant carpet of claim 1 wherein the amount of low melting point PET fiber material in the substrate layer is greater than the amount of low melting point PET fiber material in the pile face layer.

6. The flame retardant carpet of claim 1, wherein the flame retardant PET fiber material in the raised surface layer accounts for 70-95% by mass, and the low melting point PET fiber material accounts for 5-30% by mass.

7. The flame-retardant carpet as claimed in claim 1, wherein the mass percentage of the flame-retardant PET fiber material in the substrate layer is 60% -80%, and the mass percentage of the low-melting-point PET fiber material is 20% -30%.

8. The flame retardant carpet of claim 1, wherein the fiber fineness of the flame retardant PET fiber material in the raised surface layer is 4D-8D, and the fiber length is 51mm-90 mm; the fiber fineness of the low-melting-point PET fiber material in the raised surface layer is 4D, and the fiber length is 51mm-90 mm.

9. The flame retardant carpet of claim 1, wherein the fiber fineness of the flame retardant PET fiber material in the substrate layer is 8D-15D, and the fiber length is 51mm-90 mm; the fiber fineness of the low-melting-point PET fiber material in the base material layer is 4D, and the fiber length is 51mm-90 mm.

10. The flame retardant carpet of claim 1, further comprising a flame retardant latex layer, wherein the flame retardant latex layer is stacked between the raised surface layer and the sound insulation bonding layer, and the flame retardant latex layer is flame retardant by using phosphorus.

11. The flame retardant carpet of claim 10, wherein the flame retardant latex layer is a SBR flame retardant latex layer or an EVA flame retardant latex layer.

12. The flame retardant carpet of claim 1, wherein the flame retardant bottom layer is a flame retardant foamed PU layer.

13. The flame retardant carpet of claim 1, wherein the sound-proofing adhesive layer comprises a first PE film layer, a PA film layer and a second PE film layer which are sequentially stacked.

14. A method of making a flame retardant carpet, the method comprising:

mixing a low-melting-point PET fiber material and a flame-retardant PET fiber material adopting a phosphorus flame retardant, and then needling and raising to form a raised surface layer;

attaching a sound-insulating adhesive layer to the bottom surface of the raised surface layer;

mixing a low-melting-point PET fiber material and a flame-retardant PET fiber material adopting a phosphorus flame retardant system to form a base material layer, and compounding the base material layer on the surface of the sound-insulation bonding layer, which is far away from the raised surface layer;

and providing a flame-retardant bottom layer adopting phosphorus flame retardance, and compounding the flame-retardant bottom layer on the surface of the base material layer, which is deviated from the sound insulation bonding layer.

15. The method of claim 14, wherein before attaching the sound-insulating adhesive layer to the bottom surface of the pile skin layer, the method further comprises:

gluing the bottom surface of the raised surface layer to form a flame-retardant emulsion layer adopting phosphorus flame retardance;

the bottom surface laminating sound insulation adhesive linkage on gigging top layer includes:

and a sound insulation bonding layer is attached to the surface of the flame-retardant latex layer, which deviates from the raised surface layer.