A fire-retardant floor mat and method of making the same

Abstract

The application relates to the field of household supplies, in particular to a flame-retardant floor mat and a preparation method thereof. The flame-retardant floor mat comprises a yarn layer, a base cloth layer, a flame-retardant layer and an anti-skid layer arranged in sequence, the flame-retardant layer is prepared by coating flame-retardant glue, the flame-retardant glue is prepared from the following components: glue, a flame retardant, water and a thickening agent, and the preparation method comprises the following steps: step 1, tufting, tufting polyester yarn to the base cloth layer to form the yarn layer; step 2, yarn fixing, after the steps of glue adjusting-foaming, cloth feeding-gluing and drying, the flame-retardant glue is glued to the side of the base cloth layer away from the yarn layer, the yarn layer is fixed, the flame-retardant layer is formed; step 3, the anti-skid layer is compounded to the side of the base cloth layer away from the yarn layer to form the anti-skid layer; and step 4, printing, cutting and sewing are carried out to prepare the soft and high-elasticity floor mat. The application has the effect of improving the flame-retardant performance of the floor mat while ensuring that the floor mat has good printing effect.

Description

TECHNICAL FIELD

[0001] The present application relates to the field of household supplies, in particular to a flame-retardant floor mat and a preparation method thereof. BACKGROUND

[0002] Floor mats are generally used in indoor spaces such as rooms and living rooms. With the improvement of people's living standards, the items used in home life are also rich, and the use of fire is also increasing, which is accompanied by an increase in safety hazards. Since the floor mat is used indoors, it is required to have a fire-retardant effect for safety considerations.

[0003] There are two ways to achieve the fire-retardant effect of existing products. One is to use fire-retardant materials, but the color of the fire-retardant materials is generally yellow, and the color is unstable after printing, which is prone to discoloration, poor color fastness, and not suitable for printing products, limiting product diversity. The other is to spray fire-retardant additives on the surface of the floor mat, but the fire-retardant additives will decrease during use, which is not safe, and the fire-retardant additives will be washed away after several washes, thereby losing the fire-retardant effect, shortening the service life of the product, and requiring timely replacement, which is high in cost. In addition, the spraying of fire-retardant additives on the surface also makes the color of the printed product unstable, limiting product diversity. SUMMARY

[0004] In order to improve the flame-retardant performance of the floor mat while ensuring good printing effect of the floor mat, the present application provides a flame-retardant floor mat and a preparation method thereof.

[0005] In a first aspect, the present application provides a flame-retardant floor mat, which adopts the following technical solution:

[0006] The flame-retardant floor mat comprises a yarn layer, a base cloth layer, a flame-retardant layer and a non-slip layer arranged in sequence, the flame-retardant layer is prepared by coating flame-retardant glue, and the flame-retardant glue is prepared from the following components by weight: 30-40 parts of glue, 30-40 parts of flame-retardant agent, 15-25 parts of water and 1-2 parts of thickening agent.

[0007] By adopting the above technical solution, the flame-retardant floor mat of the present application sets the flame-retardant layer, rather than using flame-retardant materials to make the floor mat, so that the printing effect of the floor mat can be ensured. The flame-retardant layer is arranged on the side of the base cloth layer away from the yarn layer, and the flame-retardant layer is not arranged on the surface of the floor mat, so that the flame-retardant layer is not easily worn and torn, the flame-retardant effect of the floor mat lasts longer, and the flame-retardant layer is located on the back. When the flame-retardant layer is replenished, it will not affect the printing on the front of the floor mat, so that the flame-retardant performance of the floor mat is improved while ensuring good printing effect of the floor mat.

[0008] Preferably, the weight ratio of the glue and the flame-retardant agent is 3-4:3-4.

[0009] By adopting the technical scheme, when the proportions of the glue and the flame retardant are different, the performance of the floor mat will also be different, too little flame retardant and too much glue will result in insufficient flame retardant performance, and too little glue and too much flame retardant will result in poor compatibility of the glue and the flame retardant, the flame retardant cannot be uniformly dispersed in the glue, and the adhesion strength of the fixed yarn layer and the base cloth layer is affected, and the performance of the flame retardant is also affected.

[0010] Preferably, the glue is one or a combination of VAE glue, EVA glue and PVC glue.

[0011] Preferably, the base cloth layer is high-temperature-resistant polyester non-woven fabric, and the specification of the base cloth layer is 70-100 g / m 2 .

[0012] By adopting the technical scheme, the base cloth layer is high-temperature-resistant polyester non-woven fabric, which can improve the flame retardant performance of the floor mat, and the specification of the base cloth layer is limited, so that the processing performance of the floor mat is better.

[0013] Preferably, the yarn layer is formed by tufting polyester yarn on the base cloth layer, the count of the polyester yarn is 2500D-3500D, the fineness of a single polyester fiber in the polyester yarn is 7.5-8.75 dtex, and the number of the polyester fibers in the polyester yarn is 300-400F.

[0014] By adopting the technical scheme, the specification of the yarn is limited, so that the floor mat has better printing effect and comfort, and has certain flame retardant performance.

[0015] Preferably, the flame retardant comprises DOP, zinc borate, antimony trioxide and decabromodiphenyl ethane, and the mass ratio of the DOP, zinc borate, antimony trioxide and decabromodiphenyl ethane is 3-4:1:1:1-3.

[0016] By adopting the technical scheme, DOP is a flame retardant with good flame retardant performance; zinc borate and antimony trioxide are both flame-retardant fillers with good flame retardant performance, and when they are used together, they can have better flame retardant performance; decabromodiphenyl ethane can slow down the burning speed and reduce the surface temperature of the fabric when it burns, and it can also inhibit combustion; the bromine content of decabromodiphenyl ethane is high, and it has good thermal stability, and produces less harmful products to the environment during combustion and thermal cracking, and it is more environmentally friendly; the mass ratio of DOP, zinc borate, antimony trioxide and decabromodiphenyl ethane will affect the flame retardant performance of the flame retardant, and the application provides an optimal mass ratio of DOP, zinc borate, antimony trioxide and decabromodiphenyl ethane, so that the flame retardant has better flame retardant performance.

[0017] Preferably, the fire-retardant glue further comprises 1-2 parts of a silane coupling agent, the silane coupling agent being one or a combination of coupling agent KH-550, coupling agent KH-570 and coupling agent KH-550.

[0018] By adopting the technical scheme, the silane coupling agent can introduce carbon-carbon double bonds on the surface of the fire retardant, so that the fire retardant can strengthen the connection strength and compatibility with the glue, thereby improving the fire-retardant performance of the fire-retardant glue.

[0019] In a second aspect, the application provides a preparation method of a fire-retardant floor mat, which adopts the following technical scheme:

[0020] A preparation method of a fire-retardant floor mat, comprising the following steps:

[0021] Step 1: tufting, tufting polyester yarns onto a base cloth layer to form a yarn layer;

[0022] Step 2: yarn fixing, after the steps of glue mixing-foaming, cloth feeding-gluing and drying, the fire-retardant glue is glued to the side of the base cloth layer away from the yarn layer to fix the yarn layer and form a fire-retardant layer;

[0023] Step 3: the anti-slip layer is compounded to the side of the base cloth layer away from the yarn layer to form an anti-slip layer;

[0024] Step 4: printing, cutting and sewing are performed to prepare a soft and high-elasticity floor mat.

[0025] By adopting the technical scheme, through the yarn fixing process, the glue is applied to the side of the base cloth layer away from the yarn layer, which not only strengthens and fixes the yarn layer, but also enables the floor mat to have good fire-retardant performance without affecting printing.

[0026] Preferably, in step 2, the glue mixing-foaming process comprises mixing and stirring the accurately measured glue, fire retardant, water and thickening agent for 10-15 minutes at a speed of 150-250 rad / s, so that the components are uniformly mixed and foaming occurs, and the fire-retardant glue is prepared for standby.

[0027] Preferably, the cloth feeding-gluing process comprises uniformly applying the prepared fire-retardant glue to the side of the base cloth layer away from the yarn layer to fix the yarn layer and the base cloth layer, and the application amount of the fire-retardant glue is 150-250 g / m 2 .

[0028] By adopting the technical scheme, by controlling the preparation and gluing process of the glue, the fire-retardant performance of the fire-retardant glue is better, and the overall weight and appearance of the floor mat can be more suitable. DETAILED DESCRIPTION

[0029] In order to make the purposes, features and advantages of the present disclosure more obvious and easy to understand, the technical solutions in the embodiments of the present disclosure are clearly and completely described below. Obviously, the described embodiments are only some of the embodiments of the present disclosure, but not all. Based on the embodiments in the present disclosure, all other embodiments obtained by those skilled in the art without creative work are within the scope of protection of the present disclosure.

[0030] Preparation examples of raw materials and / or intermediates

[0031] Preparation example 1

[0032] Base cloth layer: high-temperature-resistant polyester non-woven fabric is selected as the base cloth layer, and is cut into a size of 1m x 1m. The size after cutting is 85g / m 2 .

[0033] Preparation example 2

[0034] Anti-slip layer: acrylic fabric is selected as the anti-slip layer, and is cut into a size of 1m x 1m. The size after cutting is 120g / m 2 The type of the anti-slip layer can be replaced according to actual needs, and the present application does not limit the specific type of the anti-slip layer.

[0035] Preparation example 3

[0036] Yarn layer: polyester continuous bulk filament yarn is selected as the yarn layer, the count of which is 3000D, the fineness of a single polyester fiber is 8.5dtex, and the number of fibers is 350F. Embodiment

[0037] Embodiment 1

[0038] A preparation method of a flame-retardant floor mat, comprising the following steps:

[0039] Step 1: tufting, using a tufting machine to tuft the polyester yarn onto the base cloth layer, the stitch length of tufting is 0.1 inch, the needle density is 50 needles / 10cm, forming a yarn layer;

[0040] Step 2: solidifying the yarn, going through the glue adjusting-foaming, cloth laying-gluing, and drying steps, wherein the glue adjusting-foaming process comprises adding glue, flame retardant, water, and thickening agent into a stirrer, wherein the glue is VAE glue, 0.3 kg of which is added, the flame retardant is DOP, zinc borate, antimony trioxide, and decabromodiphenyl ethane, 0.2 kg, 0.067 kg, 0.067 kg, and 0.067 kg of DOP, zinc borate, antimony trioxide, and decabromodiphenyl ethane are added respectively, 0.2 kg of water is added, the thickening agent is alkali swelling thickening agent for acrylic acid, 0.015 kg of which is added, and the mixture is stirred for 15 minutes at a speed of 200 rad / s, so that the components are uniformly mixed and foaming phenomenon occurs, and flame-retardant glue is prepared for standby use; the cloth laying-gluing process comprises uniformly coating the prepared flame-retardant glue on the side of the base cloth layer away from the yarn layer, so that the yarn layer and the base cloth layer are fixed, and the coating amount of the flame-retardant glue is 150 g / m 2 Then, drying is performed in a drying machine at 180°C for 20 min to form a flame-retardant layer.

[0041] Step 3: the anti-skid layer is compounded to the side of the base cloth layer away from the yarn layer, and the base cloth layer and the anti-skid layer are bonded using TPE glue to form an anti-skid layer.

[0042] Step 4: printing, cutting, and sewing are performed according to requirements to prepare a flame-retardant floor mat with a size of 1 m x 1 m.

[0043] Example 4

[0044] Example 4 differs from Example 1 in that Step 2: solidifying the yarn, going through the glue adjusting-foaming, cloth laying-gluing, and drying steps, wherein the glue adjusting-foaming process comprises adding glue, flame retardant, water, silane coupling agent, and thickening agent into a stirrer, wherein the glue is VAE glue, 0.3 kg of which is added, the flame retardant is DOP, zinc borate, antimony trioxide, and decabromodiphenyl ethane, 0.172 kg, 0.057 kg, 0.057 kg, and 0.114 kg of DOP, zinc borate, antimony trioxide, and decabromodiphenyl ethane are added respectively, 0.2 kg of water is added, the silane coupling agent is coupling agent KH-550, 0.015 kg of which is added, the thickening agent is alkali swelling thickening agent for acrylic acid, 0.015 kg of which is added, and the mixture is stirred for 15 minutes at a speed of 200 rad / s, so that the components are uniformly mixed and foaming phenomenon occurs, and flame-retardant glue is prepared for standby use; the cloth laying-gluing process comprises uniformly coating the prepared flame-retardant glue on the side of the base cloth layer away from the yarn layer, so that the yarn layer and the base cloth layer are fixed, and the coating amount of the flame-retardant glue is 150 g / m 2 Then, drying is performed in a drying machine at 180°C for 20 min to form a flame-retardant layer.

[0045] Example 5

[0046] Example 5 differs from Example 1 in that: Step 2: fixing the yarn, through the steps of glue mixing-foaming, cloth coating-gluing, drying, wherein the glue mixing-foaming process comprises adding glue, flame retardant, water, silane coupling agent and thickening agent into a stirrer, wherein the glue is VAE glue, 0.3 kg is added, the flame retardant is DOP, zinc borate, antimony trioxide and decabromodiphenyl ethane, DOP, zinc borate, antimony trioxide and decabromodiphenyl ethane are added respectively 0.229 kg, 0.057 kg, 0.057 kg and 0.057 kg, water is added 0.2 kg, the silane coupling agent is selected from coupling agent KH-550, 0.015 kg is added, the thickening agent is selected from acrylic acid alkali swelling thickening agent, 0.015 kg is added, and the mixture is stirred for 15 minutes at a speed of 200 rad / s, so that the components are uniformly mixed and foaming phenomenon occurs, and the prepared flame retardant glue is prepared; the cloth coating-gluing process comprises uniformly coating the prepared flame retardant glue on the side of the base fabric layer away from the yarn layer, so that the yarn layer and the base fabric layer are fixed, and the coating amount of the flame retardant glue is 150 g / m 2 Then, drying in a drying machine at 180°C for 20 min to form a flame retardant layer.

[0047] Example 6

[0048] Example 6 differs from Example 1 in that: Step 2: fixing the yarn, through the steps of glue mixing-foaming, cloth coating-gluing, drying, wherein the glue mixing-foaming process comprises adding glue, flame retardant, water, silane coupling agent and thickening agent into a stirrer, wherein the glue is VAE glue, 0.3 kg is added, the flame retardant is DOP, zinc borate, antimony trioxide and decabromodiphenyl ethane, DOP, zinc borate, antimony trioxide and decabromodiphenyl ethane are added respectively 0.178 kg, 0.044 kg, 0.044 kg and 0.134 kg, water is added 0.2 kg, the silane coupling agent is selected from coupling agent KH-550, 0.015 kg is added, the thickening agent is selected from acrylic acid alkali swelling thickening agent, 0.015 kg is added, and the mixture is stirred for 15 minutes at a speed of 200 rad / s, so that the components are uniformly mixed and foaming phenomenon occurs, and the prepared flame retardant glue is prepared; the cloth coating-gluing process comprises uniformly coating the prepared flame retardant glue on the side of the base fabric layer away from the yarn layer, so that the yarn layer and the base fabric layer are fixed, and the coating amount of the flame retardant glue is 150 g / m 2 Then, drying in a drying machine at 180°C for 20 min to form a flame retardant layer.

[0049] Example 7

[0050] Example 7 differs from Example 1 in that: Step 2: fixing the yarn, through the steps of glue mixing-foaming, cloth coating-gluing, drying, wherein the glue mixing-foaming process comprises adding glue, flame retardant, water, silane coupling agent and thickening agent into a stirrer, wherein the glue is VAE glue, 0.3 kg is added, the flame retardant is DOP, zinc borate, antimony trioxide and decabromodiphenyl ethane, DOP, zinc borate, antimony trioxide and decabromodiphenyl ethane are added respectively 0.2 kg, 0.05 kg, 0.05 kg and 0.1 kg, 0.2 kg of water is added, the silane coupling agent is selected from coupling agent KH-550, 0.015 kg is added, the thickening agent is selected from acrylic acid alkali swelling thickening agent, 0.015 kg is added, and the mixture is stirred for 15 minutes at a speed of 200 rad / s, so that the components are uniformly mixed and foaming phenomenon occurs, and the prepared flame retardant glue is prepared; the cloth coating-gluing process comprises uniformly coating the prepared flame retardant glue on the side of the base cloth layer away from the yarn layer, so that the yarn layer and the base cloth layer are fixed, and the coating amount of the flame retardant glue is 150 g / m 2 Then, drying in a drying machine at 180°C for 20 min to form a flame retardant layer.

[0051] Example 8

[0052] Example 8 differs from Example 1 in that: Step 2: fixing the yarn, through the steps of glue mixing-foaming, cloth coating-gluing, drying, wherein the glue mixing-foaming process comprises adding glue, flame retardant, water, silane coupling agent and thickening agent into a stirrer, wherein the glue is VAE glue, 0.3 kg is added, the flame retardant is DOP, zinc borate, antimony trioxide and decabromodiphenyl ethane, DOP, zinc borate, antimony trioxide and decabromodiphenyl ethane are added respectively 0.214 kg, 0.062 kg, 0.062 kg and 0.062 kg, 0.2 kg of water is added, the silane coupling agent is selected from coupling agent KH-550, 0.015 kg is added, the thickening agent is selected from acrylic acid alkali swelling thickening agent, 0.015 kg is added, and the mixture is stirred for 15 minutes at a speed of 200 rad / s, so that the components are uniformly mixed and foaming phenomenon occurs, and the prepared flame retardant glue is prepared; the cloth coating-gluing process comprises uniformly coating the prepared flame retardant glue on the side of the base cloth layer away from the yarn layer, so that the yarn layer and the base cloth layer are fixed, and the coating amount of the flame retardant glue is 150 g / m 2 Then, drying in a drying machine at 180°C for 20 min to form a flame retardant layer.

[0053] Example 9

[0054] Example 9 differs from Example 1 in that: Step 2: fixing the yarn, through the steps of glue mixing-foaming, cloth coating-gluing, drying, wherein the glue mixing-foaming process comprises adding glue, flame retardant, water, silane coupling agent and thickening agent into a stirrer, wherein the glue is VAE glue, 0.3 kg is added, the flame retardant is DOP, zinc borate, antimony trioxide and decabromodiphenyl ethane, DOP, zinc borate, antimony trioxide and decabromodiphenyl ethane are added respectively 0.165 kg, 0.047 kg, 0.047 kg and 0.141 kg, 0.2 kg of water is added, the silane coupling agent is selected from coupling agent KH-550, 0.015 kg is added, the thickening agent is selected from acrylic acid alkali swelling thickening agent, 0.015 kg is added, and the mixture is stirred for 15 minutes at a speed of 200 rad / s, so that the components are uniformly mixed and foaming phenomenon occurs, and the prepared flame retardant glue is prepared; the cloth coating-gluing process comprises uniformly coating the prepared flame retardant glue on the side of the base fabric layer away from the yarn layer, so that the yarn layer and the base fabric layer are fixed, and the coating amount of the flame retardant glue is 150 g / m 2 Then, drying in a drying machine at 180°C for 20 min to form a flame retardant layer.

[0055] Example 10

[0056] Example 10 differs from Example 1 in that: Step 2: fixing the yarn, through the steps of glue mixing-foaming, cloth coating-gluing, drying, wherein the glue mixing-foaming process comprises adding glue, flame retardant, water, silane coupling agent and thickening agent into a stirrer, wherein the glue is VAE glue, 0.3 kg is added, the flame retardant is DOP, zinc borate, antimony trioxide and decabromodiphenyl ethane, DOP, zinc borate, antimony trioxide and decabromodiphenyl ethane are added respectively 0.187 kg, 0.053 kg, 0.053 kg and 0.107 kg, 0.2 kg of water is added, the silane coupling agent is selected from coupling agent KH-550, 0.015 kg is added, the thickening agent is selected from acrylic acid alkali swelling thickening agent, 0.015 kg is added, and the mixture is stirred for 15 minutes at a speed of 200 rad / s, so that the components are uniformly mixed and foaming phenomenon occurs, and the prepared flame retardant glue is prepared; the cloth coating-gluing process comprises uniformly coating the prepared flame retardant glue on the side of the base fabric layer away from the yarn layer, so that the yarn layer and the base fabric layer are fixed, and the coating amount of the flame retardant glue is 150 g / m 2 Then, drying in a drying machine at 180°C for 20 min to form a flame retardant layer.

[0057] Example 11

[0058] Example 11 differs from Example 1 in that: Step 2: fixing the yarn, through the steps of glue mixing-foaming, cloth coating-gluing, drying, wherein the glue mixing-foaming process comprises adding glue, flame retardant, water, silane coupling agent and thickening agent into a stirrer, wherein the glue is VAE glue, 0.4 kg is added, the flame retardant is DOP, zinc borate, antimony trioxide and decabromodiphenyl ethane, 0.19 kg, 0.04 kg, 0.04 kg and 0.08 kg of DOP, zinc borate, antimony trioxide and decabromodiphenyl ethane are added respectively, 0.2 kg of water is added, the silane coupling agent is selected from coupling agent KH-550, 0.015 kg is added, the thickening agent is selected from acrylic acid alkali swelling thickening agent, 0.015 kg is added, and the mixture is stirred for 15 minutes at a speed of 200 rad / s, so that the components are uniformly mixed and foaming phenomenon occurs, and the prepared flame retardant glue is prepared; the cloth coating-gluing process comprises uniformly coating the prepared flame retardant glue on the side of the base fabric layer away from the yarn layer, so that the yarn layer and the base fabric layer are fixed, and the coating amount of the flame retardant glue is 150 g / m 2 Then, drying in a drying machine at 180°C for 20 min to form a flame-retardant layer.

[0059] Example 12

[0060] Example 12 differs from Example 1 in that: Step 2: fixing the yarn, through the steps of glue mixing-foaming, cloth coating-gluing, drying, wherein the glue mixing-foaming process comprises adding glue, flame retardant, water, silane coupling agent and thickening agent into a stirrer, wherein the glue is VAE glue, 0.35 kg is added, the flame retardant is DOP, zinc borate, antimony trioxide and decabromodiphenyl ethane, 0.163 kg, 0.047 kg, 0.047 kg and 0.093 kg of DOP, zinc borate, antimony trioxide and decabromodiphenyl ethane are added respectively, 0.2 kg of water is added, the silane coupling agent is selected from coupling agent KH-550, 0.015 kg is added, the thickening agent is selected from acrylic acid alkali swelling thickening agent, 0.015 kg is added, and the mixture is stirred for 15 minutes at a speed of 200 rad / s, so that the components are uniformly mixed and foaming phenomenon occurs, and the prepared flame retardant glue is prepared; the cloth coating-gluing process comprises uniformly coating the prepared flame retardant glue on the side of the base fabric layer away from the yarn layer, so that the yarn layer and the base fabric layer are fixed, and the coating amount of the flame retardant glue is 150 g / m 2 Then, drying in a drying machine at 180°C for 20 min to form a flame-retardant layer.

[0061] Example 13

[0062] Example 13 differs from Example 1 in that: Step 2: fixing the yarn, going through the glue adjusting-foaming, cloth laying-gluing, drying steps, wherein the glue adjusting-foaming process comprises adding glue, flame retardant, water, silane coupling agent and thickening agent into a stirrer, wherein the glue is VAE glue, 0.35 kg is added, the flame retardant is DOP, zinc borate, antimony trioxide and decabromodiphenyl ethane, 0.163 kg, 0.047 kg, 0.047 kg and 0.093 kg of DOP, zinc borate, antimony trioxide and decabromodiphenyl ethane are added respectively, 0.2 kg of water is added, the silane coupling agent is coupling agent KH-550, 0.015 kg is added, the thickening agent is acrylic alkali swelling thickening agent, 0.015 kg is added, and the mixture is stirred for 15 minutes at a speed of 200 rad / s, so that the components are uniformly mixed and foaming phenomenon occurs, and the flame-retardant glue is prepared for standby; the cloth laying-gluing process comprises uniformly coating the prepared flame-retardant glue on the side of the base cloth layer away from the yarn layer, so that the yarn layer and the base cloth layer are fixed, and the coating amount of the flame-retardant glue is 250 g / m 2 Then, drying in a drying machine at 180°C for 25 min to form a flame-retardant layer.

[0063] Example 14

[0064] Example 14 differs from Example 1 in that: Step 2: fixing the yarn, going through the glue adjusting-foaming, cloth laying-gluing, drying steps, wherein the glue adjusting-foaming process comprises adding glue, flame retardant, water, silane coupling agent and thickening agent into a stirrer, wherein the glue is VAE glue, 0.35 kg is added, the flame retardant is DOP, zinc borate, antimony trioxide and decabromodiphenyl ethane, 0.163 kg, 0.047 kg, 0.047 kg and 0.093 kg of DOP, zinc borate, antimony trioxide and decabromodiphenyl ethane are added respectively, 0.2 kg of water is added, the silane coupling agent is coupling agent KH-550, 0.015 kg is added, the thickening agent is acrylic alkali swelling thickening agent, 0.015 kg is added, and the mixture is stirred for 15 minutes at a speed of 200 rad / s, so that the components are uniformly mixed and foaming phenomenon occurs, and the flame-retardant glue is prepared for standby; the cloth laying-gluing process comprises uniformly coating the prepared flame-retardant glue on the side of the base cloth layer away from the yarn layer, so that the yarn layer and the base cloth layer are fixed, and the coating amount of the flame-retardant glue is 200 g / m 2 Then, drying in a drying machine at 180°C for 22 min to form a flame-retardant layer.

[0065] Comparative Example

[0066] Comparative Example 1

[0067] The comparative example differs from Example 1 in that:

[0068] Step 2: solidifying the yarn, through the steps of glue mixing-foaming, cloth coating-gluing, and drying, wherein the glue mixing-foaming process comprises adding glue, water, and thickening agent into a stirrer, wherein the glue is VAE glue, 0.7 kg of glue is added, 0.2 kg of water is added, and 0.015 kg of acrylic alkali swelling thickening agent is added, and the mixture is stirred for 15 minutes at a speed of 200 rad / s, so that the components are uniformly mixed and foaming occurs, to prepare a solidified yarn glue for standby; the cloth coating-gluing process comprises uniformly coating the prepared solidified yarn glue on the side of the base cloth layer away from the yarn layer, so that the yarn layer is fixed with the base cloth layer, and the coating amount of the solidified yarn glue is 150 g / m 2 Then, drying in a drying machine at 180°C for 20 min to form a flame-retardant layer.

[0069] Comparative Example 2

[0070] Comparative Example 2 and Example 1 differ in that Step 2: solidifying the yarn, through the steps of glue mixing-foaming, cloth coating-gluing, and drying, wherein the glue mixing-foaming process comprises adding glue, flame retardant, water, and thickening agent into a stirrer, wherein the glue is VAE glue, 0.3 kg of glue is added, the flame retardant is DOP, zinc borate, antimony trioxide, and decabromodiphenyl ethane, 0.2 kg, 0.067 kg, 0.067 kg, and 0.067 kg of DOP, zinc borate, antimony trioxide, and decabromodiphenyl ethane are added respectively, 0.2 kg of water is added, and 0.015 kg of acrylic alkali swelling thickening agent is added, and the mixture is stirred for 15 minutes at a speed of 200 rad / s, so that the components are uniformly mixed and foaming occurs, to prepare a flame-retardant glue for standby; the cloth coating-gluing process comprises uniformly coating the prepared flame-retardant glue on the side of the base cloth layer away from the yarn layer, so that the yarn layer is fixed with the base cloth layer, and the coating amount of the flame-retardant glue is 100 g / m 2 Then, drying in a drying machine at 180°C for 15 min to form a flame-retardant layer.

[0071] Comparative Example 3

[0072] Comparative Example 3 differs from Example 1 in that Step 2: fixing the yarn, the process of glueing and foaming, cloth coating and glueing, drying step, wherein the glueing and foaming process comprises adding glue, flame retardant, water and thickening agent into a stirrer, wherein the glue is VAE glue, 0.3 kg is added, the flame retardant is DOP, zinc borate, antimony trioxide and decabromodiphenyl ethane, 0.2 kg, 0.067 kg, 0.067 kg and 0.067 kg of DOP, zinc borate, antimony trioxide and decabromodiphenyl ethane are added respectively, 0.2 kg of water is added, the thickening agent is selected from alkali swelling thickening agent, 0.015 kg is added, and the mixture is stirred for 15 minutes at a speed of 200 rad / s, so that the components are uniformly mixed and foaming occurs, and the prepared flame retardant glue is prepared; the cloth coating and glueing process comprises uniformly coating the prepared flame retardant glue on the side of the base fabric layer away from the yarn layer, so that the yarn layer and the base fabric layer are fixed, and the coating amount of the flame retardant glue is 300 g / m 2 Then, the drying machine is used to dry at 180℃ for 30min to form a flame retardant layer.

[0073] Performance test

[0074] Test 1: flame retardant performance, according to GB / T 11049-2008 “Carpet combustion performance room temperature tablet test method”, the carpet combustion performance tester is used to test the flame retardant performance of Examples 1-14 and Comparative Examples 1-3 before and after washing 10 times, each example and comparative example is tested eight times, and finally the maximum damage length of each sample is measured, and the average value of each group is taken.

[0075] Test 2: printing effect, the tester directly observes the printing on the surface of the mat, and evaluates the color difference and printing pattern presentation effect.

[0076] Test 3: pull-out force: according to QB / T 1090-2001 “Test method for carpet tuft pull-out force”, the carpet tuft pull-out force tester is used to test the yarn layer pull-out force of the samples of Examples 1-14 and Comparative Examples 1-3.

[0077] Table 1: performance test of Examples 1-14 and Comparative Examples 1-3

[0078]

[0079] It can be seen from Examples 1, 4-14 and Comparative Examples 1-3 and Table 1 that the method of the present application is used to make the mat, which can greatly reduce the influence of the printing effect of the mat, and can give the mat good flame retardant performance and tuft pull-out force, and using this method, the mat still has good flame retardant performance after multiple washing.

[0080] It can be seen from the experimental data that the addition of the coupling agent improves the flame retardant performance and the wash resistance of the flame retardant function, and the floor mat has very durable and good flame retardant performance. It can be seen from the comparison of Examples 1 and 4-10 and Comparative Example 1 that the flame retardant of the application has very good flame retardant performance, and according to the adjustment of the components in the flame retardant, the improvement of the flame retardant performance and the wash resistance of the flame retardant effect also have different effects. The ratio of the components in the flame retardant in Example 10 improves the flame retardant performance and the wash resistance of the flame retardant effect better.

[0081] It can be seen from Examples 11-12 that when the ratio of glue and flame retardant is different, the improvement of the flame retardant performance and the wash resistance of the flame retardant effect also have different effects. Too little flame retardant reduces the flame retardant performance, and too much flame retardant has poor dispersion performance, and the flame retardant is difficult to continuously improve. The ratio of glue and flame retardant in Example 12 improves the flame retardant performance and the wash resistance of the flame retardant effect better. It can be seen from Examples 13-14 that when the coating amount of the flame retardant glue is different, the flame retardant performance and the tuft pull force are also different. However, when the coating amount reaches a certain amount, the improvement of the flame retardant performance and the pull force is limited, so the coating amount of the flame retardant glue in Example 14 is better.

[0082] It should be understood that various forms of the flow shown above can be used to reorder, add or delete steps. For example, each step described in the present disclosure can be executed in parallel, sequentially or in a different order, as long as the desired results of the technical solutions disclosed in the present disclosure can be achieved, and the present disclosure does not limit this.

[0083] The above is only a specific embodiment of the present disclosure, but the protection scope of the present disclosure is not limited thereto. Any person skilled in the art can easily think of changes or replacements within the technical scope disclosed in the present disclosure, which should be covered within the protection scope of the present disclosure. Therefore, the protection scope of the present disclosure should be subject to the protection scope of the claims.

Claims

1. A flame-retardant floor mat, characterized in that: It includes a yarn layer, a base fabric layer, a flame retardant layer and an anti-slip layer arranged in sequence. The flame retardant layer is prepared by coating with flame retardant adhesive. The flame retardant adhesive is prepared by comprising the following components in parts by weight: 30-40 parts adhesive, 30-40 parts flame retardant, 15-25 parts water and 1-2 parts thickener. The coating amount of the flame-retardant adhesive is 150-250g / ㎡; The flame-retardant layer is located between the base fabric layer and the anti-slip layer. The flame retardant includes DOP, zinc borate, antimony trioxide and decabromodiphenyl ethane, and the mass ratio of DOP, zinc borate, antimony trioxide and decabromodiphenyl ethane is 3-4:1:1:1-3.

2. The flame-retardant floor mat according to claim 1, characterized in that: The weight ratio of the adhesive to the flame retardant is 3-4:3-4.

3. The flame-retardant floor mat according to claim 1, characterized in that: The adhesive is one or more of VAE adhesive, EVA adhesive, and PVC adhesive.

4. A flame-retardant floor mat according to claim 1, characterized in that: The base fabric layer is a high-temperature resistant polyester nonwoven fabric with a specification of 70-100g / ㎡.

5. A flame-retardant floor mat according to claim 1, characterized in that: The yarn layer is formed by tufting polyester yarn onto the base fabric layer. The count of the polyester yarn is 2500D-3500D, the fineness of a single polyester fiber in the polyester yarn is 7.5-8.75dtex, and the number of polyester fibers in the polyester yarn is 300-400F.

6. A flame-retardant floor mat according to claim 1, characterized in that: The flame-retardant adhesive also includes 1-2 parts of a silane coupling agent, wherein the silane coupling agent is one or more combinations of coupling agent KH-550, coupling agent KH-570 and coupling agent KH-550.

7. A method for preparing a flame-retardant floor mat according to any one of claims 1-6, characterized in that: Includes the following steps: Step 1: Tucking, tucking polyester yarn onto the base fabric layer to form a yarn layer; Step 2: Fixing the yarn. After the steps of mixing adhesive, foaming, fabric application, coating adhesive, and drying, the flame retardant adhesive is applied to the side of the base fabric layer away from the yarn layer to fix the yarn layer and form a flame retardant layer. Step 3: Lay the anti-slip layer onto the side of the base fabric layer away from the yarn layer to form the anti-slip layer; Step 4: Print, cut and sew to prepare a soft and highly elastic floor mat.

8. The method for preparing a flame-retardant floor mat according to claim 7, characterized in that: The fabric-coating process includes uniformly coating the prepared flame-retardant adhesive onto the side of the base fabric layer away from the yarn layer, thereby fixing the yarn layer to the base fabric layer.

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