Preparation process of a flame-resistant artificial leather

Abstract

The present invention discloses a preparation process of a flame-resistant artificial leather, which relates to the technical field of artificial leather. The process includes the following steps: S1, preparing a flame-resistant coating liquid; S2, respectively manufacturing a base cloth layer and a PVC resin surface layer; S3, coating the flame-resistant coating liquid on the PVC resin surface layer to form a flame-resistant PVC resin surface layer; S4, laminating the flame-resistant PVC resin surface layer on the base cloth layer to form a flame-resistant artificial leather. The present invention can greatly improve the flame-resistant performance of the artificial leather.

Description

Technical Field

[0001] The present invention relates to the technical field of artificial leather, and particularly to a preparation process of a flame-resistant artificial leather. Background Art

[0002] Artificial leather is a plastic product that resembles leather in appearance and feel and can be used instead of leather. It is usually based on a fabric substrate and coated with synthetic resins and various plastic additives. Artificial leather can be processed according to different requirements of strength, wear resistance, cold resistance, color, luster, pattern, etc., and has the characteristics of a wide variety of colors and patterns, good waterproof performance, neat edges, high utilization rate, and relatively low price compared to genuine leather. Therefore, artificial leather is widely used in the fields of automobiles, furniture, home furnishings, etc.

[0003] Traditional artificial leather materials mostly use polyvinyl chloride (abbreviated as PVC), and PVC is a flammable material, which brings great potential safety hazards to people's lives and property. Therefore, how to prepare flame-resistant artificial leather is one of the problems that need to be solved urgently. Summary of the Invention

[0004] In order to solve at least one technical problem mentioned in the background art, the purpose of the present invention is to provide a preparation process of a flame-resistant artificial leather to improve the flame resistance of artificial leather.

[0005] To achieve the above purpose, the present invention provides the following technical solutions:

[0006] A preparation process of a flame-resistant artificial leather includes the following steps:

[0007] S1, preparing a flame-resistant coating liquid;

[0008] S2, respectively making a base fabric layer and a PVC resin surface layer;

[0009] S3, coating the flame-resistant coating liquid on the PVC resin surface layer to form a flame-resistant PVC resin surface layer;

[0010] S4, laminating the flame-resistant PVC resin surface layer on the base fabric layer to form a flame-resistant artificial leather.

[0011] Further, the flame-resistant coating liquid includes waterborne polyurethane resin, antimony trioxide, ammonium polyphosphate, curing agent, diisononyl phthalate, and heat stabilizer.

[0012] Further, the flame-resistant coating liquid includes 50 - 100 parts by weight of waterborne polyurethane resin, 22 - 30 parts by weight of antimony trioxide, 15 - 25 parts by weight of ammonium polyphosphate, 10 - 22 parts by weight of curing agent, 5 - 9 parts by weight of diisononyl phthalate, and 10 - 17 parts by weight of heat stabilizer.

[0013] Further, the heat stabilizer uses basic lead sulfite.

[0014] Furthermore, the preparation method of the flame-retardant coating liquid is as follows:

[0015] S11, Put the aqueous polyurethane resin, ammonium polyphosphate, heat stabilizer and pure water into a heating furnace, and set the temperature in the heating furnace to 80 - 125 °C;

[0016] S12, Add diisononyl phthalate and stir for 30 minutes; then add antimony trioxide and stir for another 30 minutes;

[0017] S13, Lower the temperature in the heating furnace to 38 - 45 °C;

[0018] S14, Put the curing agent into the furnace and stir for 10 minutes to form the flame-retardant coating liquid.

[0019] Furthermore, the PVC resin surface layer includes a first surface layer, a second surface layer and a third surface layer bonded in sequence; a plurality of first ventilation holes are distributed on the first surface layer; chambers are arranged at positions corresponding to the first ventilation holes on one side where the second surface layer and the third surface layer are bonded, the middle parts of the two side walls of the chamber are bonded, so that the area of the second surface layer at the chamber is separated from the first surface layer, and a plurality of second ventilation holes are arranged on the two side walls of the chamber.

[0020] Furthermore, the aperture of the first ventilation hole is 0.8 - 1.2 mm, and the hole pitch is 8 - 12 mm.

[0021] Furthermore, the second ventilation holes are formed by pulling the slits on the two side walls of the chamber.

[0022] Furthermore, the forming method of the second ventilation holes is as follows:

[0023] S21, Respectively set semi-grooves at positions corresponding to the first ventilation holes on the second surface layer and the third surface layer;

[0024] S22, Cut the bottom of the semi-groove to form a slit;

[0025] S23, Lay the second surface layer on the first surface layer and bond at positions outside the semi-grooves;

[0026] S24, Apply glue at the middle of the semi-groove on the second surface layer;

[0027] S25, Lay the third surface layer on the second surface layer and bond at positions outside the semi-grooves to form the chamber;

[0028] S26, Press the middle of the semi-groove on the third surface layer to bond the middle parts of the two side walls of the chamber, and the slit is pulled to form the second ventilation holes.

[0029] Furthermore, the coating area of the flame-resistant coating liquid includes: the outer side of the first surface layer and the outer side of the second surface layer corresponding to the chamber position.

[0030] The present invention also provides a flame-resistant artificial leather, which includes a base cloth layer and a PVC resin surface layer. The PVC resin surface layer includes a first surface layer, a second surface layer, and a third surface layer that are adhesively bonded in sequence. A plurality of first ventilation holes are distributed on the first surface layer. Chambers are provided at positions corresponding to the first ventilation holes on one side where the second surface layer and the third surface layer are adhesively bonded. The middle parts of the two side walls of the chamber are adhesively bonded, so that the area of the second surface layer at the chamber is separated from the first surface layer. A plurality of second ventilation holes are provided on the two side walls of the chamber.

[0031] Compared with the prior art, the beneficial effects of the present invention are:

[0032] 1. The present invention coats a flame-resistant coating liquid on the PVC resin surface layer, so that the manufactured artificial leather has good fireproof and flame-retardant effects, and avoids the situation that the artificial leather burns rapidly after encountering an open flame when applied to other products.

[0033] 2. The present invention proposes a new flame-resistant coating liquid and a corresponding preparation method to improve the flame resistance of the artificial leather.

[0034] 3. The PVC resin surface layer of the present invention has good air permeability through the combination of the first ventilation holes and the second ventilation holes usually. When encountering an open flame, the temperature rises, and the adhesive parts on the two side walls of the chamber are separated, closing the first ventilation holes, thereby reducing the air circulation and organizing the further spread of the fire to a certain extent. BRIEF DESCRIPTION OF THE DRAWINGS

[0035] Figure 1 It is a flowchart of the overall method of an embodiment of the present invention.

[0036] Figure 2 It is a flowchart of the preparation method of the flame-resistant coating liquid of an embodiment of the present invention.

[0037] Figure 3 It is a flowchart of the forming method of the second ventilation hole of an embodiment of the present invention.

[0038] Figure 4 It is a structural schematic diagram of the flame-resistant artificial leather of an embodiment of the present invention.

[0039] Figure 5 It is a laying schematic diagram of the first surface layer and the second surface layer of an embodiment of the present invention.

[0040] Figure 6 It is Figure 5 a partial schematic diagram of the semi-grooved position in

[0041] Figure 7Schematic diagram of the laying of the second surface layer and the third surface layer according to an embodiment of the present invention.

[0042] Figure 8 Schematic diagram of the chamber formation according to the present invention.

[0043] Figure 9 For Figure 8 Partial schematic diagram of the position of the middle chamber.

[0044] In the figure: 1. Base fabric layer; 2. PVC resin surface layer; 21. First surface layer; 211. First ventilation hole; 22. Second surface layer; 221. Chamber; 222. Second ventilation hole; 221'. Semi-groove; 222'. Crack; 23. Third surface layer. Specific implementation manners

[0045] The technical solutions in the embodiments of the present invention will be clearly and completely described below. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all the embodiments. All other embodiments obtained by those of ordinary skill in the art based on the embodiments of the present invention without creative efforts shall fall within the protection scope of the present invention.

[0046] Please refer to Figure 1 , this embodiment provides a preparation process of a flame-retardant artificial leather, including the following steps:

[0047] S1. Prepare a flame-retardant coating liquid;

[0048] The flame-retardant coating liquid includes waterborne polyurethane resin, antimony trioxide, ammonium polyphosphate, curing agent, diisononyl phthalate and heat stabilizer. Specifically, the flame-retardant coating liquid includes 50 parts of waterborne polyurethane resin, 22 parts of antimony trioxide, 15 parts of ammonium polyphosphate, 10 parts of curing agent, 5 parts of diisononyl phthalate and 10 parts of heat stabilizer by weight; the heat stabilizer is preferably basic lead sulfite.

[0049] As Figure 2 shown, the preparation method of the flame-retardant coating liquid is as follows:

[0050] S11. Put the corresponding parts of waterborne polyurethane resin, ammonium polyphosphate, heat stabilizer and 20 parts of pure water into a heating furnace, and set the temperature in the heating furnace to 80 °C;

[0051] S12. Add diisononyl phthalate, stir at a speed of 150 r / min for 30 minutes; then add antimony trioxide, and stir at a speed of 150 r / min for another 30 minutes;

[0052] S13. Lower the temperature in the heating furnace to 38 °C;

[0053] S14. Put the curing agent into the furnace and stir at a speed of 500 r / min for 10 minutes to form a flame-resistant coating liquid.

[0054] S2. As Figures 4 to 9 shown, make the base fabric layer 1 and the PVC resin surface layer 2 respectively;

[0055] As Figure 4 shown, the PVC resin surface layer 2 includes a first surface layer 21, a second surface layer 22 and a third surface layer 23 which are adhesively bonded in sequence.

[0056] A number of first ventilation holes 211 are distributed on the first surface layer 21; the second surface layer 22 and the third surface layer 23 are symmetrical to each other, and a chamber 221 is arranged at a position corresponding to the first ventilation hole 211 on the side where they are adhesively bonded. The middle parts of the two side walls of the chamber 221 are adhesively bonded, so that the area of the second surface layer 22 at the chamber 221 is separated from the first surface layer 21. A number of second ventilation holes 222 are arranged on the two side walls of the chamber 221. Through this setting, it can ensure good air permeability usually; when encountering an open fire, the temperature rises, and the adhesively bonded part of the two side walls of the chamber is relatively weak locally, resulting in the separation of the adhesively bonded part. At this time, the side wall of the chamber 221 of the second surface layer 22 unfolds towards the first surface layer 21. After unfolding, the positions of the first ventilation holes 211 and the second ventilation holes 222 are staggered, resulting in the closure of the first ventilation holes 211, thereby reducing the air circulation and organizing the further spread of the fire to a certain extent.

[0057] Preferably, the aperture of the first ventilation hole is 0.8 - 1.2 mm, and the hole pitch is 8 - 12 mm.

[0058] The second ventilation hole is formed by pulling the cracks on the two side walls of the chamber.

[0059] As Figure 3 shown, the forming method of the second ventilation hole is as follows:

[0060] S21. As Figure 5 shown, a semi-groove 221' is arranged on the second surface layer 22 at a position corresponding to the first ventilation hole 211; the structure of the third surface layer 23 is symmetrical to that of the second surface layer 22, and the semi-groove is also arranged in the same way.

[0061] S22. As Figure 6 shown, cut the bottom of the semi-groove 221' to form a crack 222';

[0062] S23. Lay the second surface layer 22 on the first surface layer 21 and bond at positions outside the semi-groove 221'.

[0063] S24. Apply glue at the middle point of the semi-groove 221' of the second surface layer 22;

[0064] S25, as shown in Figure 7 and Figure 8 shown, lay the third surface layer 23 on the second surface layer 22, and bond at positions corresponding to those outside the semi-groove 221' to form the chamber 221;

[0065] S26, as shown in Figure 9 shown, press the middle part of the semi-groove of the third surface layer 23 to bond the middle parts of the two side walls of the chamber 221, and the crack 222' is pulled to form the second ventilation hole 222. The circled part marked by the central dotted line in the figure is the bonding position.

[0066] It should be noted that in order to ensure that the first surface layer 21 can be relatively flat when the middle parts of the two side walls of the chamber 221 are bonded and the second surface layer 22 is bent, in this embodiment, the thickness of the first surface layer 21 is set to be greater than that of the second surface layer 22. Specifically, the thickness of the first surface layer 21 is 2 - 3 times that of the second surface layer 22.

[0067] S3, apply the flame-retardant coating liquid to the PVC resin surface layer 2 to form a flame-retardant PVC resin surface layer; the coating area of the flame-retardant coating liquid includes: the outside of the first surface layer and the outside of the second surface layer corresponding to the chamber position.

[0068] S4, bond the flame-retardant PVC resin surface layer onto the base cloth layer 1 to form a flame-retardant artificial leather.

[0069] Embodiment Two:

[0070] On the basis of Embodiment One, only change the composition mass fraction ratio of the flame-retardant coating liquid, specifically as follows:

[0071] The flame-retardant coating liquid includes 75 parts by weight of waterborne polyurethane resin, 26 parts of antimony trioxide, 20 parts of ammonium polyphosphate, 16 parts of curing agent, 7 parts of diisononyl phthalate, and 14 parts of heat stabilizer.

[0072] Embodiment Three:

[0073] On the basis of Embodiment One, only change the composition mass fraction ratio of the flame-retardant coating liquid, specifically as follows:

[0074] The flame-retardant coating liquid includes 100 parts by weight of waterborne polyurethane resin, 30 parts of antimony trioxide, 25 parts of ammonium polyphosphate, 22 parts of curing agent, 9 parts of diisononyl phthalate, and 17 parts of heat stabilizer.

[0075] Conduct a combustion test on the flame-retardant artificial leathers made in the above three embodiments. Take an artificial leather of 8cm * 8cm * 1cm in size, place it on an alcohol lamp and ignite for 5 minutes, and observe the experimental results. The results of Embodiment One and Embodiment Two are that there is local swelling and a small amount of smoke is generated, while the result of Embodiment Three is that a large amount of smoke is generated and there are obvious combustion marks.

[0076] It is obvious to those skilled in the art that the present invention is not limited to the details of the above-described exemplary embodiments, and that the present invention can be implemented in other specific forms without departing from the spirit or essential characteristics of the present invention. Therefore, in all respects, the embodiments should be regarded as exemplary and non-restrictive. The scope of the present invention is defined by the appended claims rather than the above description. Accordingly, all changes that fall within the meaning and scope of the equivalent elements of the claims are intended to be embraced within the present invention.

Claims

1. A preparation process of a flame-resistant artificial leather, characterized in that, It includes the following steps: S1. Prepare a flame-retardant coating liquid; S2. Make a base fabric layer and a PVC resin surface layer respectively; S3. Coat the flame-retardant coating liquid on the PVC resin surface layer to form a flame-retardant PVC resin surface layer; S4. Bond the flame-retardant PVC resin surface layer onto the base fabric layer to form a flame-retardant artificial leather; The PVC resin surface layer includes a first surface layer, a second surface layer and a third surface layer which are adhesively bonded in sequence; a plurality of first ventilation holes are distributed on the first surface layer; chambers are arranged at positions corresponding to the first ventilation holes on one side where the second surface layer and the third surface layer are adhesively bonded, the middle parts of the two side walls of the chamber are adhesively bonded, so that the area of the second surface layer at the chamber is separated from the first surface layer, and a plurality of second ventilation holes are arranged on the two side walls of the chamber. When encountering an open flame, the temperature rises, and the adhesively bonded parts of the two side walls of the chamber come off to close the first ventilation holes.

2. The preparation process of the flame-retardant artificial leather according to claim 1, characterized in that, The flame-retardant coating liquid includes waterborne polyurethane resin, antimony trioxide, ammonium polyphosphate, curing agent, diisononyl phthalate and heat stabilizer.

3. The preparation process of the flame-retardant artificial leather according to claim 2, characterized in that, The flame-retardant coating liquid includes, by weight, 50-100 parts of waterborne polyurethane resin, 22-30 parts of antimony trioxide, 15-25 parts of ammonium polyphosphate, 10-22 parts of curing agent, 5-9 parts of diisononyl phthalate and 10-17 parts of heat stabilizer.

4. The preparation process of the flame-retardant artificial leather according to claim 2 or 3, characterized in that, The heat stabilizer uses basic lead sulfite.

5. The preparation process of the flame-retardant artificial leather according to claim 1, characterized in that, The preparation method of the flame-retardant coating liquid is as follows: S11. Put waterborne polyurethane resin, ammonium polyphosphate, heat stabilizer and pure water into a heating furnace, and set the temperature in the heating furnace to 80-125°C; S12. Add diisononyl phthalate and stir for 30 minutes; then add antimony trioxide and stir for another 30 minutes; S13. Lower the temperature in the heating furnace to 38-45°C; S14. Put the curing agent into the furnace and stir for 10 minutes to form the flame-retardant coating liquid.

6. The preparation process of the flame-retardant artificial leather according to claim 1, characterized in that, The aperture of the first ventilation hole is 0.8-1.2 mm, and the hole pitch is 8-12 mm.

7. The preparation process of the flame-retardant artificial leather according to claim 1, characterized in that, The second ventilation hole is formed by pulling the cracks on the two side walls of the chamber.

8. The preparation process of the flame-retardant artificial leather according to claim 7, characterized in that, The forming method of the second ventilation hole is as follows: S21. Respectively set semi-grooves at positions corresponding to the first ventilation holes on the second surface layer and the third surface layer; S22. Cut the bottom of the semi-groove to form a crack; S23. Lay the second surface layer on the first surface layer and bond at positions outside the semi-grooves; S24. Apply glue at the middle point of the semi-groove on the second surface layer; S25. Lay the third surface layer on the second surface layer and bond at positions outside the semi-grooves to form the chamber; S26. Press the middle part of the semi-groove of the third surface layer to make the middle parts of the two side walls of the chamber adhesively bonded, and the crack is pulled to form the second ventilation hole.

9. The preparation process of the flame-retardant artificial leather according to claim 1, characterized in that, The coating area of the flame-retardant coating liquid includes: the outside of the first surface layer.

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