High-performance flame-retardant coating stitch-bonded fabric and preparation method thereof

Abstract

The invention discloses a high-performance flame-retardant coating stitch-bonded fabric and a preparation method thereof, and relates to the field of textile manufacturing, and the preparation method comprises the following steps: firstly, forming a fiber web; the fiber webs are laid in a crossed mode, the number of laid layers is 2-6, and gray fabric is obtained; the preparation method comprises the following steps: weighing 20-50 parts by weight of acrylic resin, 10-35 parts by weight of an inorganic flame-retardant material, 0.5-1.5 parts by weight of ammonia water and water, and mixing to obtain a mixed raw material; the scraper type foaming coating is prepared by mixing the raw materials; coating the scraper type foaming coating on the surface of the gray fabric, and then drying and shaping the coated gray fabric to obtain the high-performance flame-retardant coating stitch-bonded fabric; according to the high-performance flame-retardant coating stitch-bonded fabric and the preparation method thereof, through the combined action of the flame-retardant viscose fibers and inorganic flame-retardant materials, combustion is effectively inhibited, heat transmission is isolated, and fire spreading is delayed.

Description

Technical Field

[0001] The invention relates to textile manufacturing technology, and in particular to a high-performance flame-retardant coated stitched fabric and a preparation method thereof. Background Art

[0002] In the mattress cover textile sector, with improved living standards and heightened awareness of fire safety, demand for flame-retardant mattress covers is growing. Flame-retardant mattress covers can effectively reduce fire risks and protect lives and property, particularly in public places like hotels, hospitals, and nursing homes, as well as in homes.

[0003] Currently, mattress cover textiles are primarily flame-retardant by adding flame retardants or blending them with flame-retardant fibers. For example, some mattress covers achieve this by adding halogenated flame retardants to the fabric, but these produce toxic and harmful gases when burned. Other mattress covers use a blend of flame-retardant fibers and conventional fibers, but these have limited flame retardancy and may affect the fabric's feel and comfort.

[0004] Existing flame-retardant mattress cover textiles lack flame retardancy and washability. After repeated washing, the flame retardant effect decreases significantly. Furthermore, while some products achieve flame retardancy, they sacrifice comfort properties such as breathability and flexibility, making them difficult to meet consumer demands for both safe and comfortable mattress covers. Summary of the Invention

[0005] The object of the present invention is to provide a high-performance flame-retardant coated stitched fabric and a preparation method thereof, so as to solve the above-mentioned deficiencies in the prior art.

[0006] In order to achieve the above object, the present invention provides the following technical solution: a method for preparing a high-performance flame-retardant coated stitched fabric, comprising the following steps:

[0007] S1. First, take 10-30 parts of polyester staple fibers, 30-90 parts of cellulose fibers, and 10-30 parts of polyester filaments by weight; then, open and card the polyester staple fibers, cellulose fibers, and polyester filaments to form a fiber web;

[0008] S2. Cross-laying the fiber web to a number of 2-6 layers, and preliminarily reinforcing the cross-laid fiber web by needles of a needling machine to obtain a reinforced fiber web; and stitching the reinforced fiber web into a whole using a stitch-bonding machine to obtain a grey fabric;

[0009] S3. Weigh 20-50 parts of acrylic resin, 10-35 parts of inorganic flame retardant material, 0.5-1.5 parts of ammonia water and water in parts by weight and mix them to obtain a mixed raw material;

[0010] S4, stirring the mixed raw materials for 30min-60min to obtain a coating raw material; then adding a foaming agent to the coating raw material with a foam ratio of 2-6, and mixing well to obtain a scraper-type foaming coating;

[0011] S5. Applying a blade-type foaming coating to the surface of the grey fabric, and then drying the coated grey fabric. After drying, heat setting is performed to obtain a high-performance flame-retardant coated stitched fabric.

[0012] Furthermore, the cellulose fiber described in S1 is flame retardant viscose fiber.

[0013] Furthermore, the inorganic flame retardant material in S3 includes at least one of a carbon-containing inorganic material, an aluminum-containing inorganic material, a magnesium-containing inorganic material, and a silicate.

[0014] Furthermore, the drying temperature in S5 is 120°C-160°C.

[0015] Furthermore, the heat setting temperature in S5 is set to 140°C-150°C.

[0016] A high-performance flame-retardant coated stitched fabric is prepared by the preparation method.

[0017] Compared with the existing technology, the present invention provides a high-performance flame-retardant coated stitched fabric and its preparation method. Through the combined action of cellulose fibers (especially flame-retardant viscose fibers) and inorganic flame-retardant materials in the fiber raw materials, a carbonized layer and an expanded carbonaceous layer are formed at high temperatures, effectively isolating the propagation of oxygen and heat, and delaying the spread of fire.

[0018] Polyester staple fibers and polyester filaments give the stitch-woven fabric high strength and wear resistance. Cross-stacking and needle-punching reinforcement processes allow the fibers to be tightly combined to form a solid whole. At the same time, acrylic resin enhances the coating's flexibility and impact resistance, improving its overall physical and mechanical properties. The foam coating imparts thermal insulation properties. The preparation method has clear parameters and is easy to control, ensuring stable product quality. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] In order to more clearly illustrate the embodiments of the present application or the technical solutions in the prior art, the following briefly introduces the drawings required for use in the embodiments. Obviously, the drawings described below are only some embodiments described in the present invention. For ordinary technicians in this field, other drawings can also be obtained based on these drawings.

[0020] Figure 1 A schematic diagram of the overall preparation process of the stitch-bonded fabric provided in Example 1 of the present invention;

[0021] Figure 2 This is a schematic diagram of the flame retardant performance test results of the stitch-woven fabric provided in Example 3 of the present invention. DETAILED DESCRIPTION

[0022] In order to enable those skilled in the art to better understand the technical solution of the present invention, the present invention will be further described in detail below with reference to the accompanying drawings.

[0023] Example 1:

[0024] See also Figure 1 A method for preparing a high-performance flame-retardant coated stitched fabric comprises the following steps:

[0025] S1. First, take 10-30 parts of polyester staple fibers, 30-90 parts of cellulose fibers, and 10-30 parts of polyester filaments by weight; then, open and card the polyester staple fibers, cellulose fibers, and polyester filaments to form a fiber web;

[0026] S2. Cross-laying the fiber web to a number of 2-6 layers, and preliminarily reinforcing the cross-laid fiber web by needles of a needling machine to obtain a reinforced fiber web; and stitching the reinforced fiber web into a whole using a stitch-bonding machine to obtain a grey fabric;

[0027] S3. Weigh 20-50 parts of acrylic resin, 10-35 parts of inorganic flame retardant material, 0.5-1.5 parts of ammonia water and water in parts by weight and mix them to obtain a mixed raw material;

[0028] S4, stirring the mixed raw materials for 30min-60min to obtain a coating raw material; then adding a foaming agent to the coating raw material with a foam ratio of 2-6, and mixing well to obtain a scraper-type foaming coating;

[0029] S5. Applying a blade-type foaming coating to the surface of the grey fabric, and then drying the coated grey fabric. After drying, heat setting is performed to obtain a high-performance flame-retardant coated stitched fabric.

[0030] Example 2:

[0031] This embodiment provides a technical solution based on the first embodiment: a high-performance flame-retardant coated stitched fabric, which is prepared by a method for preparing a high-performance flame-retardant coated stitched fabric.

[0032] In terms of fiber raw materials, cellulose fiber (especially when it is flame retardant viscose fiber) is used. This type of fiber itself has certain flame retardant properties, which can delay the spread of fire and thus play a flame retardant role.

[0033] In terms of coating, it contains inorganic flame retardant materials (carbon-containing inorganics, aluminum-containing inorganics, magnesium-containing inorganics, silicates, etc.). At high temperatures, aluminum hydroxide will decompose to produce water vapor, absorb a large amount of heat, and reduce the surface temperature of the material. At the same time, the generated aluminum oxide can cover the surface of the material and play a role in isolating the air; magnesium hydroxide will also absorb heat when decomposed by heat, and the generated magnesium oxide also has a good barrier effect.

[0034] The use of polyester staple fibers and filaments gives stitchbonds high strength and abrasion resistance. Polyester fibers are strong enough to withstand significant tensile forces, making them less susceptible to breakage during use. Furthermore, after cross-laying, needling, and stitchbonding, the fibers become more tightly entangled and bonded, forming a robust overall structure. This improves the fabric's physical and mechanical properties, making it adaptable to a variety of complex environments and mechanical operations.

[0035] The acrylic resin in the coating enhances the flexibility and impact resistance of stitch-woven fabrics. Acrylic resin has excellent film-forming properties, allowing the coating to evenly coat the fabric surface and provide strong adhesion to the fibers. When subjected to external impact, the coating shares stress with the fibers, minimizing damage to the fabric.

[0036] The use of a foam coating can impart thermal insulation properties to woven fabrics. The foamed coating contains numerous tiny bubbles that effectively block heat conduction, giving the fabric excellent insulation properties. This makes it suitable for applications requiring thermal insulation, such as wrapping high-temperature pipes.

[0037] The method's clear parameters for each step make the entire production process easy to control, ensuring stable and consistent product quality. Furthermore, by adjusting the fiber ratio, coating material formulation, and process parameters, the properties of the stitch-bonded fabric can be easily adjusted to suit different usage requirements and application scenarios.

[0038] Example 3:

[0039] See also Figure 2 This embodiment provides a technical solution based on the first or second embodiment: flame retardant performance test.

[0040] The flame retardant test was conducted on high-performance flame retardant coated stitched fabric. The test conditions were methane gas, the fire source height was 20 cm, and the continuous ignition time was 50 seconds.

[0041] See also Figure 2After removing the fire source, the high-performance flame-retardant coated stitched fabric showed no signs of dripping, cracking, or afterflaming. Measurements showed that the peak temperature of the high-performance flame-retardant coated stitched fabric during the test was below 440°C, successfully achieving a stable heat barrier. This demonstrates that the high-performance flame-retardant coated stitched fabric possesses excellent flame retardancy, effectively slowing the spread of fire when exposed to a fire source, providing reliable protection for fire protection and other applications.

[0042] Example 4:

[0043] A method for preparing a high-performance flame-retardant coated stitched fabric comprises the following steps:

[0044] A1. First, 10-30 parts by weight of polyester staple fibers, 30-90 parts by weight of cellulose fibers, and 10-30 parts by weight of polyester filaments are prepared; the polyester staple fibers, cellulose fibers, and polyester filaments are then opened and carded to form a fiber web; the fiber web is cross-laid in 2-6 layers, and the cross-laid fiber web is preliminarily reinforced by needles of a needle loom to obtain a reinforced fiber web; the reinforced fiber web is sewn together using a stitchbonding machine to obtain a grey fabric;

[0045] A2. Add N,N-dimethylformamide solvent to polyurethane powder, and gradually accelerate from 300 r / min to 1000 r / min within 30 minutes to obtain a transparent polyurethane sol solution (TPU solution); then add an intumescent flame retardant with ammonium polyphosphate (APP), trimeramine (MEL), and pentaerythritol (PER) as the system {m(APP):m(MEL):m(PER) is (8-12):(6-10):(1-3)} to the polyurethane sol solution, and add APP, PER, MEL in the order of addition; accelerate from 300 r / min to 500 r / min within 90 minutes and stir until dissolved to obtain a milky white intumescent flame retardant polyurethane solution (IFR / TPU solution).

[0046] A3. Add butyl acetate to the aluminum-silver paste and stir at a speed of 200-300 r / min for 20-30 minutes to obtain a uniform silver-gray liquid (Al solution).

[0047] A4. Add the prepared IFR / TPU solution to the AI ​​solution, add lignin powder and silane coupling agent KH550 while stirring, and adjust the viscosity of the intumescent flame retardant polyurethane silver paste solution to 3000cP-6000cP with N,N-dimethylformamide solvent or butyl acetate solvent. After the solution is prepared, let it stand for 20-30 minutes to obtain an intumescent flame retardant polyurethane silver paste solution (IFR / TPU / AI solution).

[0048] A5. Add a foaming agent and a foam stabilizer to the 1FR / TPU / AI solution. Use a foaming device to form a certain mass of foam from the solution at a foam ratio of 1:2. Then evenly apply the foam to the surface of the grey fabric. After the foaming coating, control the temperature and gradually increase the temperature to shape the solution onto the grey fabric to obtain a high-performance flame-retardant coated stitched fabric.

[0049] Polyether polyol or fatty alcohol polyoxyethylene ether is used as a foaming agent, and silicone or alkyl alcohol amide is used as a foam stabilizer.

[0050] The molecular structure of polyether polyols may contain benzene rings, which make them highly reactive and can shorten the foaming time; they can improve the flame retardant effect of the coating, and have high output and low cost. In addition, their industrial manufacturing technology is mature and can effectively control production costs.

[0051] The ether bond in the fatty alcohol polyoxyethylene ether molecule is not easily destroyed by acid or alkali, has high stability, can be used in a wide pH range, and is adaptable to different process conditions;

[0052] It has good emulsifying properties, which can better mix the foaming agent with other ingredients to form a stable emulsion, which is conducive to the formation and uniform distribution of foam and improves the uniformity of the coating; it meets environmental protection requirements and is environmentally friendly; it has good compatibility with other surfactants and can synergize with various ingredients to optimize the performance of the foaming system; it has good low-temperature washing performance and is not affected by water hardness, making it more suitable for washing synthetic fibers and can be used in a variety of formula systems.

[0053] Silicone foam stabilizers have good surface activity, can effectively reduce the gas-liquid interfacial tension, make the foam stable, extend the life of the foam, and ensure that the foam does not break or collapse during the coating process; they have good compatibility with a variety of systems and can synergize with foaming agents and other additives to form a stable foam system, improving the uniformity and stability of the coating; they can make the coating have better waterproofness, weather resistance and flexibility, and improve the overall performance of the coating.

[0054] Alkyl alcohol amide foam stabilizers can form a protective film on the foam surface to prevent the foam from bursting, effectively stabilize the foam, and keep the foam in good shape during the coating process, ensuring the thickness and uniformity of the coating; they have a certain thickening effect, which can increase the viscosity of the foaming system, improve the fluidity of the system, facilitate the coating and operation of the foam, and make the foam adhere more evenly to the surface of the grey fabric; they can enhance the flexibility and adhesion of the coating, make the coating and the grey fabric bond more tightly, and improve the wear resistance and washing resistance of the coating.

[0055] Embodiment 5:

[0056] This embodiment provides a technical solution based on the fourth embodiment: vertical combustion test.

[0057] Reference standard: "Textiles - Burning Behavior Test - Vertical Method" GB / T 5455-1997;

[0058] The measurement parameters are as follows:

[0059] Afterflame time: This refers to the time a sample continues to burn after being removed from the flame. This parameter directly reflects the textile's ability to continue burning after the fire source is removed. The longer the afterflame time, the greater the potential fire risk in actual use, as it may become a factor that helps the fire spread.

[0060] Smoldering time: This refers to the duration of slow combustion, such as smoke and carbonization, after the sample is removed from the flame, even though there is no visible flame. The smoldering stage should not be ignored, as in certain environments, smoldering textiles may trigger secondary combustion in surrounding combustibles, prolonging the fire hazard.

[0061] Damage Length: Describes the extent of damage along the length of a specimen after combustion. By measuring the damage length, we can understand the extent of flame spread within the textile and assess its fire resistance. A shorter damage length means the textile is more effective in limiting the spread of fire along its surface, posing a relatively small threat to the surrounding environment.

[0062] The specimen size is 30cm x 8cm.

[0063] Pre-test preparation: Before testing, specimens were placed in a humidified environment with a strictly controlled temperature of 20±2°C and a relative humidity of 65%±5% for 24 hours. This pre-treatment step is crucial, as air temperature and humidity can significantly affect the moisture content of textiles. Humidification at standard temperature and humidity ensures that the initial moisture content of specimens from different batches and materials is consistent, eliminating the potential for this variable to interfere with the combustion performance test results and ensuring the accuracy and comparability of subsequent test data.

[0064] Test parameters: flame height is 40mm±2mm, burning time is 12s.

[0065] When conducting a vertical combustion test, the humidity-conditioned specimen is securely mounted on a dedicated fixture to maintain a vertical position. Ignite the burner so that the flame, meeting the required flame height, accurately impacts the bottom of the specimen. Continue for 12 seconds, then quickly remove the flame. Closely observe the specimen for afterburning and smoldering, and start a timer to record the afterburning and smoldering times, respectively. After the combustion process is complete, measure the damaged length of the specimen using a gauge with millimeter graduations. Ensure the gauge fits snugly against the specimen. Measure the maximum extension of the carbonized or damaged portion along the length of the specimen to ensure data accuracy.

[0066] The experimental data results are as follows:

[0067] Afterflame time: 0s. After the flame is removed, the sample quickly stops burning, demonstrating excellent flame retardancy. It extinguishes quickly upon contact with a fire source, effectively preventing further spread of the fire. This significantly reduces fire risk and protects lives and property.

[0068] Smoldering time: 0s. The sample showed no smoldering, indicating that the textile did not produce smoldering characteristics such as continuous smoking and slow carbonization during combustion. This reduces the possibility of smoldering fires and avoids the generation of large amounts of toxic smoke, which is very beneficial for personnel evacuation and fire rescue.

[0069] Damage length: only about 1 cm. Only a very small area of ​​the sample was damaged by the flames, indicating that the flames could not spread rapidly across the sample, and the combustion was well confined to a small area. This demonstrates the excellent flame retardant properties of the textile, which can quickly curb the spread of fire upon contact with the fire source, effectively protecting the surrounding environment from fire damage, and reflects the textile's excellent performance and high reliability in fire safety.

[0070] Example 6:

[0071] This embodiment provides a technical solution based on the fourth embodiment: cone calorimetry test.

[0072] Reference standard: ISO 5660-1:2015.

[0073] Measurement parameters:

[0074] Time to Ignition (TT): This measures the time from when a material comes into contact with flame to when it begins to burn. It is a key indicator for measuring the ease with which a material can be ignited. The longer the TT, the less likely the material is to ignite and the lower the fire risk.

[0075] Heat Release Rate (HRR): reflects the amount of heat released per unit time when the material burns. It is the core parameter for measuring the growth rate of fire. The higher the HRR peak, the faster the fire spreads and the greater the danger.

[0076] Total heat release (THR): Indicates the total heat released from the start of combustion to the extinction of the material, reflecting the overall thermal hazard of material combustion.

[0077] Effective Heat Combustion (EHC): Measures the combustion efficiency of materials and involves the completeness of combustion. A high EHC value indicates high combustion efficiency and more complete heat release.

[0078] Smoke production (TSP): Evaluates the amount of smoke produced by material combustion, which is directly related to visibility at the fire scene and the risk of smoke toxicity. A low TSP value helps reduce smoke hazards.

[0079] Mass loss rate (MLR): reflects the mass loss per unit time during material combustion and is closely related to the combustion rate and material decomposition process.

[0080] Sample size: 10cm x 10cm.

[0081] Preparation before the test: Humidity adjustment for 24 hours at a temperature of 20±2℃ and a relative humidity of 65%±5%.

[0082] Test parameters: Radiant heat flux is 50kW·m -2 .

[0083] The experimental data results are as follows:

[0084] TT is 120 seconds. A longer TT value means that the material is not easily ignited after contacting a heat source. It has good initial flame retardant properties and can effectively delay the occurrence of fire, buying more time for fire prevention and escape. The HRR peak is 80kW. A lower HRR peak indicates that the material releases heat more slowly during combustion, and the fire grows slowly, which helps to control the spread of fire and reduce the risk of fire. The THR is 30MJ. A smaller THR value indicates that the total heat released by the material during the entire combustion process is less, which means that the overall thermal hazard generated by its combustion is smaller, and the threat to the surrounding environment and personnel is relatively low. The EHC reaches 0.3, which indicates that when the material is burning, less heat is used to maintain its own combustion, and more heat may be lost in other forms or converted into harmless substances, reflecting the material's good combustion performance and energy utilization efficiency. The TSP is 15m 2 / kg, a lower TSP value indicates that the material produces less smoke during combustion, which helps to improve visibility at the fire scene and reduce the impact of smoke on personnel evacuation and fire rescue. It can also reduce the release of harmful substances in the smoke and reduce the harm to human health; the MLR is 0.02g / s. A lower MLR indicates that the material loses mass slowly during combustion, has a relatively stable structure, is not prone to rapid decomposition and combustion, and can effectively extend the fire resistance time of the material, providing more opportunities for fire fighting and personnel escape.

[0085] In summary, the material exhibited excellent fire resistance in the cone calorimetry test, and has the characteristics of good flame retardancy, low heat release, and low smoke production. It can be used in places with high fire safety requirements.

[0086] The above description is merely illustrative of certain exemplary embodiments of the present invention. It goes without saying that those skilled in the art will be able to modify the described embodiments in various ways without departing from the spirit and scope of the present invention. Therefore, the above drawings and description are illustrative in nature and should not be construed as limiting the scope of protection of the claims.

Claims

1. A method for preparing a high-performance flame-retardant coated stitched fabric, characterized in that: The steps include: S1. First, take 10-30 parts of polyester staple fibers, 30-90 parts of cellulose fibers, and 10-30 parts of polyester filaments by weight; then, open and card the polyester staple fibers, cellulose fibers, and polyester filaments to form a fiber web; S2. Cross-laying the fiber web to a number of 2-6 layers, and preliminarily reinforcing the cross-laid fiber web by needles of a needling machine to obtain a reinforced fiber web; and stitching the reinforced fiber web into a whole using a stitch-bonding machine to obtain a grey fabric; S3. Weigh 20-50 parts of acrylic resin, 10-35 parts of inorganic flame retardant material, 0.5-1.5 parts of ammonia water and water in parts by weight and mix them to obtain a mixed raw material; S4, stirring the mixed raw materials for 30min-60min to obtain a coating raw material; then adding a foaming agent to the coating raw material with a foam ratio of 2-6, and mixing well to obtain a scraper-type foaming coating; S5. Applying a blade-type foaming coating to the surface of the grey fabric, and then drying the coated grey fabric. After drying, heat setting is performed to obtain a high-performance flame-retardant coated stitched fabric.

2. The method for preparing a high-performance flame-retardant coated stitched fabric according to claim 1, characterized in that: The cellulose fiber described in S1 is flame retardant viscose fiber.

3. The method for preparing a high-performance flame-retardant coated stitched fabric according to claim 1, characterized in that: The inorganic flame retardant material in S3 includes at least one of a carbon-containing inorganic material, an aluminum-containing inorganic material, a magnesium-containing inorganic material, and a silicate.

4. The method for preparing a high-performance flame-retardant coated stitched fabric according to claim 1, characterized in that: The drying temperature in S5 is 120°C-160°C.

5. The method for preparing a high-performance flame-retardant coated stitched fabric according to claim 1, characterized in that: The heat setting temperature in S5 is 140°C-150°C.

6. A high performance flame retardant coated stitched fabric, characterized in that: The compound is prepared by the preparation method according to any one of claims 1 to 5.

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