Environment-friendly flame-retardant carpet material and preparation method thereof

Abstract

The invention relates to the field of carpet materials, in particular to an environment-friendly flame-retardant carpet material and a preparation method thereof. The environment-friendly flame-retardant carpet material comprises the following raw materials in parts by weight: 50-55 parts of jute, 40-45 parts of modified polypropylene, 7-10 parts of polyurethane, 30-32 parts of an adhesive and 5-7 parts of calcium carbonate. According to the invention, the flame-retardant yarns with high flame-retardant property can be prepared from the modified polypropylene, and the flame-retardant yarns are tufted on the jute backing, so that the whole carpet has a better flame-retardant effect from top to bottom.

Description

Technical Field

[0001] This invention relates to the field of carpet materials, and in particular to an environmentally friendly flame-retardant carpet material and its preparation method. Background Technology

[0002] Many common carpets are made of PVC. PVC-backed carpets have strong anti-corrosion, anti-moth, and anti-static properties, and will not warp or deform even after long-term use. However, PVC produces toxic fumes when burned, is not environmentally friendly, and hinders safe escape in the event of a fire.

[0003] Chinese Patent Publication No. CN109822992B discloses a flame-retardant and wear-resistant carpet, comprising a carpet fabric layer, a flame-retardant layer, a carpet base layer, and a wear-resistant layer. The carpet fabric layer and the carpet base layer are made of the same material and are located on top of the carpet base layer. A flame-retardant layer is located between the carpet fabric layer and the carpet base layer, with one end connected to the carpet fabric layer and the other end connected to the carpet base layer. The wear-resistant layer is located at the bottom layer of the carpet, and the flame-retardant layer is coated on the upper surface of the carpet base layer. The carpet fabric layer and the carpet base layer have good comfort and breathability, and facilitate the application of flame-retardant coatings to the carpet base layer. The wear-resistant layer possesses good wear resistance, giving the carpet a wear-resistant function. The flame-retardant layer has excellent flame-retardant properties without affecting the carpet material. The manufacturing process is simple and low-cost, meeting the production needs of enterprises.

[0004] However, the above technical solution has the following shortcomings: the flame retardant layer is located between the carpet fabric layer and the carpet base layer. When the carpet catches fire, the carpet fabric layer will burn first. The flame retardant layer can only prevent the flame from continuing to burn to the carpet base layer. After the carpet fabric layer itself has burned out, it indicates that the flame retardant performance of the entire carpet needs to be further improved. Summary of the Invention

[0005] The purpose of this invention is to address the problems existing in the background technology by proposing an environmentally friendly flame-retardant carpet material and its preparation method. It can utilize modified polypropylene to prepare flame-retardant yarn with high flame-retardant properties, and tuft the flame-retardant yarn onto a jute backing, so that the entire carpet has a good flame-retardant effect from top to bottom.

[0006] On the one hand, the present invention proposes an environmentally friendly flame-retardant carpet material, comprising the following raw materials in parts by weight: 50-55 parts jute, 40-45 parts modified polypropylene, 7-10 parts polyurethane, 30-32 parts adhesive, and 5-7 parts calcium carbonate.

[0007] Preferably, the modified polypropylene comprises the following raw materials in parts by weight: 25-26 parts polypropylene, 4-6 parts flame retardant, 6-7 parts synergist, and 5-6 parts coupling agent.

[0008] Preferably, the flame retardant is powdered aluminum hydroxide, magnesium hydroxide or expanded graphite, the synergist is silicone, and the coupling agent is silane coupling agent or titanate coupling agent.

[0009] Preferably, the adhesive is a water-based latex or a hot melt adhesive.

[0010] On the other hand, the present invention proposes a method for preparing the above-mentioned environmentally friendly flame-retardant carpet material, comprising the following steps: S1. Modified polypropylene is melt-spun to obtain flame-retardant yarn; S2. The flame-retardant yarn is tufted onto the primary jute backing using a tufting machine to obtain the carpet surface layer. S3. Apply adhesive to the back of the carpet surface layer and attach the secondary jute backing to obtain a semi-finished carpet. S4. Pass the semi-finished carpet through an impregnation solution containing phosphorus and nitrogen flame retardants, and then dry and cure it; S5. Printing on the carpet; S6. Trim and finish the carpet.

[0011] Preferably, in preparing modified polypropylene: first, calcium carbonate, polypropylene, flame retardant, synergist, and coupling agent are premixed; then, the premixed material is fed into the feed port of a twin-screw extruder, where it is heated to a molten state inside the extruder barrel. The material is then forcefully sheared, conveyed, and mixed by two meshing, co-rotating screws, ensuring that calcium carbonate, flame retardant, synergist, and coupling agent are uniformly dispersed in the polypropylene melt; the homogenized polypropylene melt is then extruded into strips through a die and cooled in a water tank, and finally cut into uniform granular masterbatch, i.e., modified polypropylene masterbatch, by a pelletizer.

[0012] Preferably, during the extrusion process, a vacuum pump is turned on to exhaust air and remove mixed air and low-molecular-weight volatiles to prevent air bubbles from forming in the modified polypropylene masterbatch.

[0013] Preferably, the modified polypropylene masterbatch is dried and sieved to remove excessively long or fine particles.

[0014] Compared with the prior art, the present invention has the following beneficial technical effects: The present invention can use modified polypropylene to prepare flame-retardant yarn with high flame-retardant performance. In the modified polypropylene, the flame retardant is an environmentally friendly inorganic flame retardant. By tufting the flame-retardant yarn onto the jute backing, flame retardancy can be achieved from the top material of the carpet. The jute backing and adhesive also have good flame-retardant properties, so that the entire carpet has a good flame-retardant effect from top to bottom. Attached Figure Description

[0015] Figure 1 This is a flowchart illustrating the preparation method of the environmentally friendly flame-retardant carpet material according to an embodiment of the present invention. Detailed Implementation

[0016] Example 1: This example proposes an environmentally friendly flame-retardant carpet material, comprising the following raw materials by weight: 50 parts jute, 40 parts modified polypropylene, 7 parts polyurethane, 30 parts adhesive, and 7 parts calcium carbonate.

[0017] The modified polypropylene includes the following raw materials by weight: 25 parts polypropylene, 4 parts flame retardant, 6 parts synergist, and 5 parts coupling agent.

[0018] The flame retardant is powdered aluminum hydroxide, magnesium hydroxide or expanded graphite, the synergist is silicone, and the coupling agent is silane coupling agent or titanate coupling agent.

[0019] The adhesive is a water-based latex or a hot melt adhesive.

[0020] Example 2: This example proposes an environmentally friendly flame-retardant carpet material. Compared with Example 1, the environmentally friendly flame-retardant carpet material of this example includes the following raw materials by weight: 51 parts jute, 43 parts modified polypropylene, 10 parts polyurethane, 31 parts adhesive, and 5 parts calcium carbonate.

[0021] The modified polypropylene includes the following raw materials by weight: 26 parts polypropylene, 5 parts flame retardant, 7 parts synergist, and 5 parts coupling agent.

[0022] Example 3: This example proposes an environmentally friendly flame-retardant carpet material. Compared with Example 1, the environmentally friendly flame-retardant carpet material of this example includes the following raw materials by weight: 52 parts jute, 44 parts modified polypropylene, 9 parts polyurethane, 30 parts adhesive, and 7 parts calcium carbonate.

[0023] The modified polypropylene includes the following raw materials by weight: 26 parts polypropylene, 6 parts flame retardant, 6 parts synergist, and 6 parts coupling agent.

[0024] Example 4: This example proposes an environmentally friendly flame-retardant carpet material. Compared with Example 1, the environmentally friendly flame-retardant carpet material of this example includes the following raw materials by weight: 53 parts jute, 43 parts modified polypropylene, 7 parts polyurethane, 31 parts adhesive, and 5 parts calcium carbonate.

[0025] The modified polypropylene includes the following raw materials by weight: 26 parts polypropylene, 6 parts flame retardant, 6 parts synergist, and 5 parts coupling agent.

[0026] Example 5: This example proposes an environmentally friendly flame-retardant carpet material. Compared with Example 1, the environmentally friendly flame-retardant carpet material of this example includes the following raw materials by weight: 55 parts jute, 45 parts modified polypropylene, 8 parts polyurethane, 32 parts adhesive, and 5 parts calcium carbonate.

[0027] The modified polypropylene includes the following raw materials by weight: 26 parts polypropylene, 6 parts flame retardant, 7 parts synergist, and 6 parts coupling agent.

[0028] Example 6: This example proposes an environmentally friendly flame-retardant carpet material. Compared with Example 1, the environmentally friendly flame-retardant carpet material of this example includes the following raw materials by weight: 52 parts jute, 42 parts modified polypropylene, 7 parts polyurethane, 31 parts adhesive, and 6 parts calcium carbonate.

[0029] The modified polypropylene includes the following raw materials by weight: 25 parts polypropylene, 4 parts flame retardant, 7 parts synergist, and 6 parts coupling agent.

[0030] In this environmentally friendly flame-retardant carpet material, jute itself possesses certain flame-retardant properties. The modified polypropylene includes flame retardants, which enhance the flame-retardant performance of the modified polypropylene. Furthermore, calcium carbonate can be added during the preparation of the modified polypropylene to improve its rigidity and heat resistance. For the two inorganic flame retardants, aluminum hydroxide and magnesium hydroxide, they decompose and absorb heat during flame retardation, releasing water vapor, diluting flammable gases, and are non-toxic and smoke-suppressing. For the expanded graphite flame retardant, it expands upon contact with fire, forming a dense, porous carbon layer that provides heat insulation and oxygen barrier properties, resulting in good flame-retardant performance and environmental friendliness. Silicone synergists can improve flame-retardant efficiency. To improve the compatibility between the flame retardant and the polypropylene matrix, silane coupling agents or titanate coupling agents are used to surface-treat the flame retardant, making the bond between the flame retardant and the polypropylene matrix tighter and ensuring flame-retardant performance.

[0031] Example 7: Figure 1 As shown in this embodiment, a method for preparing the environmentally friendly flame-retardant carpet material described in the above embodiments includes the following steps: S1. Modified polypropylene is melt-spun to obtain flame-retardant yarn. The polypropylene raw material in the modified polypropylene is a recyclable raw material. It is more environmentally friendly to prepare modified polypropylene using recyclable raw materials. S2. The flame-retardant yarn is tufted onto the primary jute backing using a tufting machine to obtain the carpet surface layer. S3. Apply adhesive to the back of the carpet surface layer and attach the secondary jute backing to it to obtain a semi-finished carpet. In the semi-finished carpet, the primary jute backing and the secondary jute backing can ensure the thickness of the entire carpet, making it more aesthetically pleasing and with better flame retardant properties. Adhesive and polyurethane materials can be used to bond the carpet surface layer and the secondary jute backing at the same time to improve the bonding strength. S4. The semi-finished carpet is passed through an impregnation solution containing a phosphorus-nitrogen flame retardant, and then dried and cured. The phosphorus-nitrogen flame retardant can be ammonium polyphosphate, which achieves flame retardant effect through multiple mechanisms such as promoting fiber charring, insulating heat and releasing non-flammable gases. S5. According to actual production needs, use a printer to print the required pattern on the carpet. S6. Trim and finish the carpet to make it more uniform and ensure the final quality.

[0032] In preparing the modified polypropylene required in step S1: first, calcium carbonate, polypropylene, flame retardant, synergist, and coupling agent are premixed; then, the premixed material is fed into the feed port of a twin-screw extruder, where it is heated to a molten state inside the extruder barrel. The material is then powerfully sheared, conveyed, and mixed by two intermeshing, co-rotating screws, ensuring that calcium carbonate, flame retardant, synergist, and coupling agent are uniformly dispersed in the polypropylene melt. The homogenized polypropylene melt is then extruded into strips through a die and cooled in a water tank. Finally, it is cut into uniform cylindrical or flat-round granular masterbatch by a pelletizer, which is the modified polypropylene masterbatch.

[0033] During the extrusion process, the vacuum pump is turned on to exhaust air and remove mixed air and low-molecular-weight volatiles to prevent air bubbles from forming in the modified polypropylene masterbatch.

[0034] The modified polypropylene masterbatch can be dried and sieved to remove excessively long or fine particles and ensure a more uniform size.

[0035] In this preparation method, modified polypropylene can be used to prepare flame-retardant yarn with high flame-retardant properties. In the modified polypropylene, the flame retardant is an environmentally friendly inorganic flame retardant that will not produce harmful gases when exposed to fire. By tufting the flame-retardant yarn onto the jute backing, flame retardancy can be achieved starting from the top layer of the carpet. The jute backing and adhesive also have good flame-retardant properties, thus giving the entire carpet a good flame-retardant effect from top to bottom.

[0036] The embodiments of the present invention have been described in detail above with reference to the accompanying drawings. However, the present invention is not limited thereto. Various changes can be made within the scope of knowledge possessed by those skilled in the art without departing from the spirit of the present invention.

Claims

1. An environmentally friendly flame-retardant carpet material, characterized in that, Includes the following raw materials by weight: 50-55 parts jute, 40-45 parts modified polypropylene, 7-10 parts polyurethane, 30-32 parts adhesive, and 5-7 parts calcium carbonate.

2. The environmentally friendly flame-retardant carpet material according to claim 1, characterized in that, Modified polypropylene comprises the following raw materials in parts by weight: 25-26 parts polypropylene, 4-6 parts flame retardant, 6-7 parts synergist, and 5-6 parts coupling agent.

3. The environmentally friendly flame-retardant carpet material according to claim 2, characterized in that, The flame retardant is powdered aluminum hydroxide, magnesium hydroxide or expanded graphite, the synergist is silicone, and the coupling agent is silane coupling agent or titanate coupling agent.

4. The environmentally friendly flame-retardant carpet material according to claim 1, characterized in that, The adhesive is a water-based latex or a hot melt adhesive.

5. A method for preparing the environmentally friendly flame-retardant carpet material of claim 2, characterized in that, Includes the following steps: S1. Modified polypropylene is melt-spun to obtain flame-retardant yarn; S2. The flame-retardant yarn is tufted onto the primary jute backing using a tufting machine to obtain the carpet surface layer. S3. Apply adhesive to the back of the carpet surface layer and attach the secondary jute backing to obtain a semi-finished carpet. S4. Pass the semi-finished carpet through an impregnation solution containing phosphorus and nitrogen flame retardants, and then dry and cure it; S5. Printing on the carpet; S6. Trim and finish the carpet.

6. The preparation method according to claim 5, characterized in that, In the preparation of modified polypropylene: first, calcium carbonate, polypropylene, flame retardant, synergist, and coupling agent are premixed; then, the premixed material is fed into the feed port of a twin-screw extruder, where it is heated to a molten state inside the extruder barrel. The two intermeshing, co-rotating screws forcefully shear, convey, and mix the material, ensuring that calcium carbonate, flame retardant, synergist, and coupling agent are uniformly dispersed in the polypropylene melt; the homogenized polypropylene melt is then extruded into strips through a die and cooled in a water tank, before being cut into uniform granular masterbatch, i.e., modified polypropylene masterbatch, by a pelletizer.

7. The preparation method according to claim 6, characterized in that, During the extrusion process, the vacuum pump is turned on to exhaust air and remove mixed air and low-molecular-weight volatiles to prevent air bubbles from forming in the modified polypropylene masterbatch.

8. The preparation method according to claim 6, characterized in that, The modified polypropylene masterbatch is dried and sieved to remove excessively long or fine particles.

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