Flame-retardant, antibacterial and sound-insulating composite fiberboard and preparation method thereof

Abstract

The present application relates to the technical field of layered products, specifically to a flame-retardant, antibacterial, and sound-insulating composite fiberboard and a preparation method thereof, wherein the flame-retardant, antibacterial, and sound-insulating composite fiberboard is composed of a sound-insulating, flame-retardant layer, a reinforcing layer, an antibacterial, and flame-retardant layer, and a finishing layer in sequence; the sound-insulating, flame-retardant layer is made by hot-melt bonding of sisal fiber, polyester fiber, and collagen fiber, and then adding a first flame retardant to mix; the reinforcing layer is a mesh-like structure made by hot-melt bonding of aramid fiber and bamboo fiber; the antibacterial, flame-retardant layer is made by hot-pressing a mixture of raw materials including bamboo charcoal activated carbon, a second flame retardant, and volcanic rock particles; the finishing layer is a non-woven fabric surface layer; the sound-insulating, flame-retardant layer, the reinforcing layer, the antibacterial, and flame-retardant layer, and the finishing layer are bonded by adding PMMA powder and hot-baking and pressing. The present application realizes the autonomous bonding of the composite fiberboard by cross-linking different functional layers, thereby improving the flame-retardant, antibacterial, and sound-insulating properties of the composite fiberboard, while reducing the formaldehyde content of the composite fiberboard and improving the quality of the living environment.

Description

Technical Field

[0001] The present application relates to the technical field of layered products, and in particular to a flame-retardant, antibacterial, and sound-insulating composite fiberboard and a preparation method thereof. Background Art

[0002] Composite fiberboard is a synthetic material composed of fibers and other materials. It has the advantages of light weight, high strength, good stability, moisture resistance, corrosion resistance, and easy processing. It is often used for building decoration and can be used in the production of walls, ceilings, sound insulation panels, door and window frames, wall panels, and floors.

[0003] With the development of society, people have higher and higher requirements for indoor living environment. In order to meet more needs, composite fiberboards also need to be improved in function. In order to improve the comprehensive performance of composite fiberboards, such as flame retardancy, antibacterial, sound insulation, etc., the existing technology often uses multiple functional layers to bond to achieve the enhancement of the function of composite fiberboards. However, bonding requires a large amount of adhesives, which usually contain harmful gases such as formaldehyde. In the later use, harmful gases such as formaldehyde will slowly evaporate from the composite fiberboard, which will affect human health in the long run.

[0004] How to improve the bonding strength of composite fiberboard and enhance its flame retardant, antibacterial, sound insulation and other functions without using adhesives is an urgent problem to be solved. Summary of the invention

[0005] The present application aims to overcome at least one of the defects of the prior art and provide a flame retardant, antibacterial and sound insulating composite fiber board and a preparation method thereof. By cross-linking different functional layers, the self-bonding of the composite fiber board is achieved, and the flame retardant, antibacterial and sound insulating properties of the composite fiber board are improved, while the formaldehyde content of the composite fiber board can be reduced, thereby improving the quality of the living environment.

[0006] In the first aspect, the embodiment of the present application provides a flame retardant, antibacterial and sound insulating composite fiberboard, which is achieved by the following technical solutions:

[0007] The flame retardant, antibacterial and sound insulation composite fiberboard is composed of a sound insulation and flame retardant layer, a reinforcement layer, an antibacterial and flame retardant layer and a finishing layer in sequence;

[0008] The sound insulation and flame retardant layer is made by hot-melt bonding of sisal fiber, polyester fiber and collagen fiber and then adding a first flame retardant to mix;

[0009] The reinforcing layer is a mesh structure made by hot-melt bonding of aramid fiber and bamboo fiber.

[0010] The antibacterial flame retardant layer is made by hot pressing a mixture of raw materials including bamboo charcoal activated carbon, a second flame retardant and volcanic rock particles;

[0011] The facing layer is a non-woven fabric surface layer;

[0012] The sound insulation and flame retardant layer, the reinforcement layer, the antibacterial and flame retardant layer and the finishing layer are bonded by adding PMMA powder and hot baking and pressing.

[0013] The flame retardant, antibacterial and sound insulating composite fiberboard according to the embodiment of the present application has at least the following beneficial effects:

[0014] The functional layers of the flame retardant, antibacterial, and sound insulating composite fiberboard of the present application are matched by selecting specific raw materials, which are easy to cross-link and bond during heat baking and pressing. At the same time, PMMA powder is added to the contact surface of each layer. PMMA powder has a low melting point and melts during heat baking. It acts as an adhesive to tightly connect the layers of materials and improve the adhesion between the layers of materials. At the same time, based on the characteristics of PMMA itself, the hardness and wear resistance of the flame retardant, antibacterial, and sound insulating composite fiberboard can be enhanced.

[0015] The collagen fibers of the present application have the properties of microporous sound absorption and resonant sound absorption, but are short in length and poor in uniformity; the sisal fibers are longer and have large and long cell cavities, which are conducive to multiple reflections of sound waves, thereby improving the sound absorption effect. In addition, the sisal fibers are tough, elastic, friction-resistant, and acid- and alkali-resistant; the polyester fibers have high breaking strength and elastic modulus; by mixing collagen fibers with polyester fibers and sisal fibers, the prepared sound insulation and flame-retardant layer not only has excellent sound insulation effect, but is also tougher and more wear-resistant.

[0016] The aramid fiber of the present application has excellent properties such as ultra-high strength, high modulus, high temperature resistance, acid and alkali resistance, light weight, aging resistance, and long life cycle; bamboo fiber has strong toughness and wear resistance, and can also be antibacterial, moisture-absorbent, breathable, and deodorizing; by combining aramid fiber with bamboo fiber, the strength of the flame-retardant, antibacterial, and sound-insulating composite fiberboard can be enhanced, and it can also help with antibacterial and deodorizing, thereby improving the quality of the living environment.

[0017] The bamboo charcoal activated carbon of the present application has the functions of removing formaldehyde, absorbing moisture, deodorizing, preventing mildew and insects; the volcanic rock is naturally weakly alkaline, which can inhibit the formation of bacteria and mildew, and at the same time has a natural multi-level pore structure, which can actively absorb harmful gases such as formaldehyde and benzene in the air, and also has a good sound absorption effect, and has good fire resistance; the combination of bamboo charcoal activated carbon and volcanic rock particles can enhance their respective antibacterial properties and improve the ability to absorb odors, while enhancing the sound insulation, fire resistance and strength of the flame-retardant, antibacterial and sound-insulating composite fiberboard.

[0018] According to some embodiments of the present application, the thickness ratio of the sound insulation flame retardant layer, the reinforcement layer, the antibacterial flame retardant layer, and the finishing layer is: (3-5): (2-3): (1-3): 1. For example, the thickness ratio of the sound insulation flame retardant layer, the reinforcement layer, the antibacterial flame retardant layer, and the finishing layer is: 4:2:2:1.

[0019] The thickness of the sound insulation and flame retardant layer in the composite fiberboard is kept at a relatively large proportion. When noise sound waves enter the composite fiberboard, due to the porous structure of the sound insulation and flame retardant layer, the sound waves will be gradually absorbed and dissipated in the process of reflection. The thicker sound insulation and flame retardant layer also makes the internal gaps more, so that the sound waves are reflected and absorbed more times in the sound insulation and flame retardant layer, and finally the energy is converted into heat energy and dissipated, thereby enhancing the sound insulation effect of the composite fiberboard. At the same time, the thicker sound insulation and flame retardant layer can also improve the flame retardant effect and maintain the comprehensive performance of the flame retardant, antibacterial and sound insulation composite fiberboard.

[0020] According to some embodiments of the present application, the first flame retardant is a phosphate flame retardant, for example, the first flame retardant is triethyl phosphate. Triethyl phosphate has extremely low viscosity and high phosphorus content, and has a good flame retardant effect.

[0021] According to some embodiments of the present application, the average particle size of the bamboo charcoal activated carbon is 1-20 mm.

[0022] According to some embodiments of the present application, the average particle size of the volcanic rock particles is 1-2 mm.

[0023] According to some embodiments of the present application, the weight ratio of the bamboo charcoal activated carbon to the second flame retardant is (1-6):1, for example, the weight ratio of the bamboo charcoal activated carbon to the second flame retardant is 2:1.

[0024] According to some embodiments of the present application, the second flame retardant includes fumed silica and Fe3O4 powder. When the material burns, silica can form a silica cover, which has the functions of insulation and shielding, and can prevent heat transfer and escape of combustibles. The addition of fumed silica can also increase the residual carbon content of the material. As its dosage increases, the residual carbon content of the composite material gradually increases, and the carbon layer gradually becomes denser and complete, thereby improving the flame retardant performance; when subjected to thermal radiation, Fe3O4 can effectively suppress the flame, making the flame smaller and shorter, and can reduce the heat and harm caused by the flame. In addition, Fe3O4 has magnetism, and can enhance the adsorption effect when combined with bamboo charcoal activated carbon and volcanic rock particles.

[0025] Furthermore, the average particle size of the fumed silica is 25-35 nm, for example, the average particle size of the fumed silica is 30 nm. Nano-scale fumed silica can capture free radicals released by the combustion reaction and form a dense and uniform barrier layer, thereby enhancing the flame retardant effect.

[0026] Furthermore, the weight ratio of the fumed silica to the Fe3O4 powder is 1:(1-3), for example, the weight ratio of the fumed silica to the Fe3O4 powder is 1:2.

[0027] According to some embodiments of the present application, the non-woven fabric surface layer is formed by spinning polypropylene fibers into a web and then hot-rolling and bonding them.

[0028] Furthermore, the non-woven fabric surface layer is doped with functional particles.

[0029] Furthermore, the functional particles include at least one of activated carbon powder and tourmaline powder.

[0030] According to some embodiments of the present application, the average particle size of the PMMA powder does not exceed 6.5 μm. Ultrafine PMMA powder has a lower melting point and is easy to bond, while being able to increase the hardness of the flame retardant, antibacterial and sound insulation fiberboard and enhance its wear resistance and scratch resistance.

[0031] Furthermore, the average particle size of the PMMA powder is 3-6.5 μm, for example, the average particle size of the PMMA powder is 5 μm, 6.5 μm.

[0032] According to some embodiments of the present application, the antibacterial flame retardant layer also contains natural plant ingredients.

[0033] Further, the natural plant ingredients include at least one of tea tree essential oil, ravensa leaf, eucalyptus, sophora flavescens, fir essential oil, phellodendron, geranium essential oil, marjoram oil, lithospermum oil, eucalyptus oil, star anise, spearmint, hyssop essential oil, cypress essential oil, turmeric oil, litsea cubeba, oregano, angelica essential oil, wormwood essential oil, cyperus essential oil, forsythia essential oil, coptis chinensis, licorice, ephedra, rhubarb, sophora flavescens, wild chrysanthemum, lavender, chamomile essential oil, rosewood essential oil, cherry blossom essential oil, cedar essential oil, ylang-ylang oil, bergamot essential oil, vetiver essential oil, borneol essential oil, peppermint, patchouli, eucalyptus oil, osmanthus essential oil, citronella essential oil, cinnamon, garlic oil, thyme essential oil, helichrysum essential oil, turpentine, water lily, clove, and scutellaria essential oil.

[0034] In a second aspect, the present application provides a method for preparing the flame retardant, antibacterial and sound insulating composite fiberboard, which is achieved by the following technical solutions:

[0035] The method for preparing the flame retardant, antibacterial and sound insulating composite fiberboard comprises the following steps:

[0036] S1. Prepare the sound insulation and flame retardant layer, the reinforcement layer, the antibacterial and flame retardant layer and the finishing layer respectively;

[0037] S2. The sound insulation and flame retardant layer, the reinforcement layer, the antibacterial and flame retardant layer and the finishing layer are stacked in order, PMMA powder is evenly sprinkled on the contact surface of each layer during stacking, pre-pressed, and the upper and lower surfaces are heated in a drying room by hot air jetting, and then cold rolled, cooled and consolidated after leaving the drying room;

[0038] The preparation of the sound insulation and flame retardant layer in step S1 is as follows: the sisal fiber and the polyester fiber are combed into a thin fiber web by a carding unit, and then the web is laid by a cross-lapping machine and flattened by a press to form a randomly arranged sisal polyester fiber web layer of a certain thickness, and the collagen fiber is randomly laid on the sisal polyester fiber web layer to form a composite fiber web layer, and the composite fiber web layer is sent to a needle punching unit for needle punching, and the collagen fibers are all inserted into the interior of the sisal polyester fiber web layer, and after hot-melt bonding and hot rolling, the first flame retardant is used for flame retardant finishing to obtain a sound insulation and flame retardant layer;

[0039] Preparation of the antibacterial flame retardant layer in step S1: adding the bamboo charcoal activated carbon and the second flame retardant to the silane coupling agent aqueous solution, ultrasonicating and stirring to prepare a suspension; adding carboxymethyl cellulose to the suspension to prepare a slurry, and then drying and grinding to prepare a composite powder; weighing 30-40 parts by weight of volcanic rock particles, 30-40 parts by weight of clay, 4-8 parts by weight of pore-forming agent, and 35-50 parts by weight of the composite powder, mixing them evenly, adding 25-35 parts by weight of water, granulating, and preparing particles; adding soy protein adhesive and mixing, placing the mixture in a hot press, and hot pressing at 500-700°C to prepare an antibacterial flame retardant layer.

[0040] The method for preparing the flame-retardant, antibacterial and sound-insulating composite fiberboard according to the embodiment of the present application has at least the following beneficial effects:

[0041] The preparation method of the present application is to evenly sprinkle PMMA powder on the contact surface of each layer of material during stacking. PMMA powder has a low melting point and melts during heat baking, and acts as an adhesive to tightly connect the layers of material, thereby improving the adhesion between the layers of material. At the same time, based on the characteristics of PMMA itself, the hardness and wear resistance of the flame retardant, antibacterial and sound insulating composite fiberboard can be enhanced.

[0042] The preparation method of the present application inserts all the collagen fibers into the interior of the sisal polyester fiber mesh layer. Since the sisal fibers and polyester fibers are long and have large mesh openings, inserting the collagen fibers can improve the internal tightness. After hot-melt bonding, the collagen fibers, sisal fibers and polyester fibers are entangled and bonded to each other, thereby enhancing the internal bonding force of the sound insulation and flame retardant layer. After hot rolling, the internal structure is more complex, which is beneficial to the reflection, absorption and dissipation of sound waves in the sound insulation and flame retardant layer, thereby improving the sound insulation effect.

[0043] According to some embodiments of the present application, the fineness of the sisal fiber is 50-570 μm.

[0044] Furthermore, the length of the sisal fiber is 50-700 mm.

[0045] According to some embodiments of the present application, the fineness of the polyester fiber is 20-230 μm.

[0046] Furthermore, the length of the polyester fiber is 20-120 mm.

[0047] According to some embodiments of the present application, the collagen fibers are extracted from waste leather.

[0048] Furthermore, the extraction method is physical extraction.

[0049] According to some embodiments of the present application, the fineness of the collagen fibers is 12-32 μm.

[0050] Furthermore, the length of the collagen fibers is 0.5-4 mm.

[0051] According to some embodiments of the present application, the flame retardant finishing includes a first padding, a first drying, baking, washing, a second padding, and a second drying.

[0052] According to some embodiments of the present application, the pore former is a mixture of ammonium bicarbonate and starch.

[0053] Furthermore, the weight ratio of ammonium bicarbonate to starch is 3:1.

[0054] According to some embodiments of the present application, the silane coupling agent is 3-aminopropyltriethoxysilane.

[0055] According to some embodiments of the present application, the preparation of the antibacterial flame retardant layer further includes adding natural plant ingredients for mixing before hot pressing.

[0056] According to some embodiments of the present application, the reinforcement layer described in step S1 is prepared by combing and laying bamboo fibers to form a bamboo fiber mesh layer, combing and laying aramid fibers to form an aramid fiber mesh layer, and then compounding the upper and lower surfaces of the bamboo fiber mesh layer with a layer of aramid fiber mesh layer respectively, and using the front and back needle-punching method to penetrate all the aramid fibers of the aramid fiber mesh layer into the interior of the bamboo fiber mesh layer to obtain a bamboo fiber-aramid fiber composite mesh layer, and then evenly sprinkling 3-5% of polyethylene powder by weight of the bamboo fiber-aramid fiber composite mesh layer on the upper surface of the bamboo fiber-aramid fiber composite mesh layer, and finally consolidating it by hot air penetration hot melt bonding method.

[0057] The polyethylene powder of the present application has a low melting point and is used as a hot melt adhesive. The polyethylene powder is blown into the bamboo fiber and aramid fiber composite mesh layer by hot air blowing and melt-bonded, thereby enhancing the bonding effect and making the aramid fiber and bamboo fiber intertwined and bonded to form a high-strength reinforcement layer.

[0058] According to some embodiments of the present application, the preparation of the finishing layer described in step S1 is as follows: polypropylene fibers are spun into a web, and then hot-rolled and bonded to obtain the finishing layer.

[0059] Furthermore, functional particles are added to the spinning melt during the spinning web forming process.

[0060] According to some embodiments of the present application, the temperature of the thermal baking in step S2 is 110-170°C, for example, the temperature of the thermal baking is 150°C.

[0061] According to some embodiments of the present application, the heat baking time in step S2 is 1-3 hours, for example, the heat baking time is 2 hours.

[0062] According to some embodiments of the present application, the cold rolling temperature in step S2 is 5-25°C, for example, the cold rolling temperature is 20°C.

[0063] According to some embodiments of the present application, the cooling temperature in step S2 is 5-25°C, for example, the cooling temperature is 20°C.

[0064] In the third aspect, the embodiments of the present application provide the application of the flame retardant, antibacterial and sound insulation composite fiberboard in building decoration. The flame retardant, antibacterial and sound insulation composite fiberboard of the present application is used to make walls, ceilings, sound insulation boards, door and window frames, wall panels and floors, which can reduce formaldehyde content and improve the quality of the living environment while improving the flame retardant, antibacterial and sound insulation properties. BRIEF DESCRIPTION OF THE DRAWINGS

[0065] Figure 1 This is a schematic structural diagram of the flame retardant, antibacterial and sound insulating composite fiberboard according to an embodiment of the present application.

[0066] Description of reference numerals:

[0067] 1. Sound insulation and flame retardant layer; 2. Reinforcement layer; 3. Antibacterial and flame retardant layer; 4. Finishing layer. DETAILED DESCRIPTION

[0068] To make the purpose, technical solution and advantages of the present application clearer, the following will be further described in detail in conjunction with specific embodiments. The embodiments described here are only part of the embodiments of the present application and cannot be understood as limiting the scope of protection of the present application. Example 1

[0069] Preparation of flame retardant, antibacterial and sound insulation composite fiberboard:

[0070] Reference Figure 1 The method for preparing the flame retardant, antibacterial and sound insulating composite fiberboard comprises the following steps:

[0071] (1) Sisal fiber with a fineness of 50-570 μm and a length of 50-700 mm and polyester fiber with a fineness of 20-230 μm and a length of 20-120 mm are selected, and the sisal fiber and polyester fiber are combed into a relatively thin fiber web by a carding unit, and then the web is laid by a cross-lapping machine and flattened by a press to form a randomly arranged sisal polyester fiber web layer of a certain thickness; the fineness of 12-32 μm and a length of 20-120 mm obtained by physical method from waste leather are selected; The collagen fibers with a thickness of 0.5-4 mm are randomly laid on the sisal polyester fiber mesh layer to form a composite fiber mesh layer, and the composite fiber mesh layer is sent to the needling unit for needling, and the collagen fibers are all inserted into the interior of the sisal polyester fiber mesh layer, and after hot-melt bonding and hot rolling, flame retardant finishing is performed using a phosphate flame retardant, and after the first impregnation, the first drying, baking, washing, the second impregnation, and the second drying, a sound insulation flame retardant layer 1 is obtained;

[0072] (2) Combing and laying bamboo fibers to form a bamboo fiber mesh layer, combing and laying aramid fibers to form an aramid fiber mesh layer, and then compounding the upper and lower surfaces of the bamboo fiber mesh layer with a layer of aramid fiber mesh layer respectively, and using a front and back needle punching method to pierce all the aramid fibers of the aramid fiber mesh layer into the interior of the bamboo fiber mesh layer to obtain a bamboo fiber aramid fiber composite mesh layer, and then evenly sprinkling 4% of the weight of the bamboo fiber aramid fiber composite mesh layer on the upper surface of the bamboo fiber aramid fiber composite mesh layer. Finally, hot air penetration hot melt bonding method is used for consolidation, so that the aramid fibers and the bamboo fibers are intertwined and bonded to form a mesh-like reinforcement layer 2;

[0073] (3) Bamboo charcoal activated carbon with an average particle size of 1-20 mm, Fe3O4 powder, and fumed silica with an average particle size of 30 nm are mixed in a weight ratio of 6:2:1, added to an aqueous solution of 3-aminopropyltriethoxysilane, ultrasonicated and stirred to prepare a suspension; carboxymethyl cellulose is added to the suspension to prepare a slurry, which is then dried and ground to prepare a composite powder; 30 parts by weight of volcanic rock particles with an average particle size of 1-2 mm, 40 parts by weight of clay, 6 parts by weight of a mixture of ammonium bicarbonate and starch in a weight ratio of 3:1, and 50 parts by weight of the composite powder are weighed, mixed evenly, 30 parts by weight of water are added, granulated, and granules are prepared; 20 parts by weight of soy protein adhesive, 1 part by weight of tea tree essential oil, and 1 part by weight of cherry blossom essential oil are added and mixed, the mixture is placed in a hot press, and hot pressed at 700°C to prepare an antibacterial flame retardant layer 3;

[0074] (4) spinning polypropylene fibers into a web, adding activated carbon powder and tourmaline powder to the spinning melt during the spinning process, and then hot-rolling and bonding to obtain a finishing layer 4;

[0075] (5) The sound insulation and flame retardant layer 1, the reinforcement layer 2, the antibacterial and flame retardant layer 3 and the finishing layer 4 are stacked in order, and PMMA powder with an average particle size of 5 μm is evenly sprinkled on the contact surface of each layer of materials during stacking. The layers are pre-pressed and formed, and the upper and lower surfaces are heated at 150° C. for 2 h in a drying room by hot air jetting. After exiting the drying room, the layers are cold rolled at 20° C. and cooled and consolidated at 20° C. to form a flame retardant and antibacterial sound insulation composite fiberboard.

[0076] The thickness ratio of the sound insulation and flame retardant layer 1, the reinforcement layer 2, the antibacterial and flame retardant layer 3 and the finishing layer 4 in the flame retardant and antibacterial sound insulation composite fiberboard is 4:2:2:1. Example 2

[0077] Preparation of flame retardant, antibacterial and sound insulation composite fiberboard:

[0078] Reference Figure 1 The method for preparing the flame retardant, antibacterial and sound insulating composite fiberboard comprises the following steps:

[0079] (1) Sisal fiber with a fineness of 50-570 μm and a length of 50-700 mm and polyester fiber with a fineness of 20-230 μm and a length of 20-120 mm are selected, and the sisal fiber and polyester fiber are combed into a relatively thin fiber web by a carding unit, and then the web is laid by a cross-lapping machine and flattened by a press to form a randomly arranged sisal polyester fiber web layer of a certain thickness; the fineness of 12-32 μm and a length of 20-120 mm obtained by physical method from waste leather are selected; The collagen fibers with a thickness of 0.5-4 mm are randomly laid on the sisal polyester fiber mesh layer to form a composite fiber mesh layer, and the composite fiber mesh layer is sent to the needling unit for needling, and the collagen fibers are all inserted into the interior of the sisal polyester fiber mesh layer, and after hot-melt bonding and hot rolling, flame retardant finishing is performed using a phosphate flame retardant, and after the first impregnation, the first drying, baking, washing, the second impregnation, and the second drying, a sound insulation flame retardant layer 1 is obtained;

[0080] (2) Combing and laying bamboo fibers to form a bamboo fiber mesh layer, combing and laying aramid fibers to form an aramid fiber mesh layer, and then compounding the upper and lower surfaces of the bamboo fiber mesh layer with a layer of aramid fiber mesh layer respectively, and using a front and back needle punching method to pierce all the aramid fibers of the aramid fiber mesh layer into the interior of the bamboo fiber mesh layer to obtain a bamboo fiber aramid fiber composite mesh layer, and then evenly sprinkling 3% of the weight of the bamboo fiber aramid fiber composite mesh layer on the upper surface of the bamboo fiber aramid fiber composite mesh layer. Finally, hot air penetration hot melt bonding method is used to consolidate, so that the aramid fibers and the bamboo fibers are intertwined and bonded to form a mesh-like reinforcement layer 2;

[0081] (3) Bamboo charcoal activated carbon with an average particle size of 1-20 mm, Fe3O4 powder, and fumed silica with an average particle size of 30 nm are mixed in a weight ratio of 6:2:1, added to an aqueous solution of 3-aminopropyltriethoxysilane, ultrasonicated and stirred to prepare a suspension; carboxymethyl cellulose is added to the suspension to prepare a slurry, which is then dried and ground to prepare a composite powder; 40 parts by weight of volcanic rock particles with an average particle size of 1-2 mm, 30 parts by weight of clay, 4 parts by weight of a mixture of ammonium bicarbonate and starch in a weight ratio of 3:1, and 35 parts by weight of the composite powder are weighed, mixed evenly, 35 parts by weight of water are added, granulated, and granules are prepared; 20 parts by weight of soy protein adhesive, 1 part by weight of osmanthus essential oil, and 1 part by weight of Phellodendron chinense are added and mixed, the mixture is placed in a hot press, and hot pressed at 500° C. to prepare an antibacterial flame retardant layer 3;

[0082] (4) spinning polypropylene fibers into a web, adding activated carbon powder and tourmaline powder to the spinning melt during the spinning process, and then hot-rolling and bonding to obtain a finishing layer 4;

[0083] (5) The sound insulation and flame retardant layer 1, the reinforcement layer 2, the antibacterial and flame retardant layer 3 and the finishing layer 4 are stacked in order, and PMMA powder with an average particle size of 6.5 μm is evenly sprinkled on the contact surface of each layer of materials during stacking, and pre-pressed and formed, and the upper and lower surfaces are heat-dried in a drying room by hot air jet at a temperature of 170° C. for 3 h, and then cold-rolled at 20° C. and cooled and consolidated at 20° C. after leaving the drying room to make a flame retardant, antibacterial and sound insulation composite fiberboard;

[0084] The thickness ratio of the sound insulation and flame retardant layer 1, the reinforcement layer 2, the antibacterial and flame retardant layer 3 and the finishing layer 4 in the flame retardant and antibacterial sound insulation composite fiberboard is 4:2:2:1. Example 3

[0085] Preparation of flame retardant, antibacterial and sound insulation composite fiberboard:

[0086] Reference Figure 1 The method for preparing the flame retardant, antibacterial and sound insulating composite fiberboard comprises the following steps:

[0087] (1) Sisal fiber with a fineness of 50-570 μm and a length of 50-700 mm and polyester fiber with a fineness of 20-230 μm and a length of 20-120 mm are selected, and the sisal fiber and polyester fiber are combed into a relatively thin fiber web by a carding unit, and then the web is laid by a cross-lapping machine and flattened by a press to form a randomly arranged sisal polyester fiber web layer of a certain thickness; the fineness of 12-32 μm and a length of 20-120 mm obtained by physical method from waste leather are selected; The collagen fibers with a thickness of 0.5-4 mm are randomly laid on the sisal polyester fiber mesh layer to form a composite fiber mesh layer, and the composite fiber mesh layer is sent to the needling unit for needling, and the collagen fibers are all inserted into the interior of the sisal polyester fiber mesh layer, and after hot-melt bonding and hot rolling, flame retardant finishing is performed using a phosphate flame retardant, and after the first impregnation, the first drying, baking, washing, the second impregnation, and the second drying, a sound insulation flame retardant layer 1 is obtained;

[0088] (2) Combing and laying bamboo fibers to form a bamboo fiber mesh layer, combing and laying aramid fibers to form an aramid fiber mesh layer, and then compounding the upper and lower surfaces of the bamboo fiber mesh layer with a layer of aramid fiber mesh layer respectively, and using a front and back needle punching method to pierce all the aramid fibers of the aramid fiber mesh layer into the interior of the bamboo fiber mesh layer to obtain a bamboo fiber aramid fiber composite mesh layer, and then evenly sprinkling 5% of the weight of the bamboo fiber aramid fiber composite mesh layer on the upper surface of the bamboo fiber aramid fiber composite mesh layer. Finally, hot air penetration hot melt bonding method is used to consolidate, so that the aramid fibers and the bamboo fibers are intertwined and bonded to form a mesh-like reinforcement layer 2;

[0089] (3) Bamboo charcoal activated carbon with an average particle size of 1-20 mm, Fe3O4 powder, and fumed silica with an average particle size of 30 nm are mixed in a weight ratio of 6:2:1, added to an aqueous solution of 3-aminopropyltriethoxysilane, ultrasonicated and stirred to prepare a suspension; carboxymethyl cellulose is added to the suspension to prepare a slurry, which is then dried and ground to prepare a composite powder; 35 parts by weight of volcanic rock particles with an average particle size of 1-2 mm, 35 parts by weight of clay, 8 parts by weight of a mixture of ammonium bicarbonate and starch in a weight ratio of 3:1, and 45 parts by weight of the composite powder are weighed, mixed evenly, 25 parts by weight of water are added, granulated, and granules are prepared; 20 parts by weight of soy protein adhesive, 1 part by weight of lavender, and 1 part by weight of chamomile essential oil are added and mixed, the mixture is placed in a hot press, and hot pressed at 600°C to prepare an antibacterial flame retardant layer 3;

[0090] (4) spinning polypropylene fibers into a web, adding activated carbon powder and tourmaline powder to the spinning melt during the spinning process, and then hot-rolling and bonding to obtain a finishing layer 4;

[0091] (5) The sound insulation and flame retardant layer 1, the reinforcement layer 2, the antibacterial and flame retardant layer 3 and the finishing layer 4 are stacked in order, and PMMA powder with an average particle size of 3 μm is evenly sprinkled on the contact surface of each layer of materials during stacking. The layers are pre-pressed and formed, and the upper and lower surfaces are heated in a drying room by hot air jet at a temperature of 110° C. for 1 hour. After exiting the drying room, the layers are cold rolled at 20° C. and cooled and consolidated at 20° C. to form a flame retardant, antibacterial and sound insulation composite fiberboard.

[0092] The thickness ratio of the sound insulation and flame retardant layer 1, the reinforcement layer 2, the antibacterial and flame retardant layer 3 and the finishing layer 4 in the flame retardant and antibacterial sound insulation composite fiberboard is 4:2:2:1. Comparative Example 1

[0093] The common fiberboard on the market is composed of a backboard layer, a urea-formaldehyde resin adhesive layer, a core board layer, a second adhesive layer and a panel layer from bottom to top. Comparative Example 2

[0094] The composite fiberboard is made of a sound-absorbing fiber layer composed of fir wood, bamboo fiber layer, two layers of polyester fiber cotton sound insulation cotton and two layers of ceramic fiber layers cross-lapped, a flame retardant fiber layer composed of wood fiber and durable formaldehyde-free flame retardant and formaldehyde-free plywood adhesive, and a nano-graphene layer pressed together at 120°C.

[0095] The relevant properties of the fiberboards prepared in Examples 1-3 and Comparative Examples 1-2 of the present application were tested, and the testing method was as follows:

[0096] The static bending strength, elastic modulus and formaldehyde emission are tested in accordance with the standard of GB / T 18103-2022.

[0097] The flame retardant grade is tested according to the standard of GB 8624-2012.

[0098] The sound insulation performance is tested according to the standard of JC / T 2701-2022.

[0099] The test data is shown in Table 1 below:

[0100]

[0101] It can be seen from Table 1 that the flame retardant, antibacterial and sound insulating composite fiber boards prepared in Examples 1-3 of the present application have good static bending strength, elastic modulus, formaldehyde emission, sound insulation effect and flame retardant effect. With the mutual matching of specific raw material ratios and through a specific preparation process, the prepared composite fiber boards can achieve self-bonding, which improves the flame retardant, antibacterial and sound insulation properties of the composite fiber boards. At the same time, the bonding force of each layer is strong, and the formaldehyde content of the composite fiber boards can be reduced, thereby improving the quality of the living environment.

[0102] The common fiberboard on the market in Comparative Example 1 uses a large amount of adhesive, and its formaldehyde emission reaches 1.97 mg / L, which affects human health. At the same time, its sound insulation and flame retardancy are also poor.

[0103] Due to the differences in raw materials and preparation processes, the internal bonding force of the composite fiber board in Comparative Example 2 is not strong, and its static bending strength and elastic modulus are not as good as the flame retardant, antibacterial and sound insulating composite fiber board prepared in the embodiment of the present application. At the same time, the sound insulation effect is not good enough.

[0104] Although the embodiments of the present application have been shown and described, those skilled in the art will appreciate that various changes, modifications, substitutions or variations may be made to the embodiments without departing from the principles and purpose of the present application, and that the technical solutions after these changes, modifications, substitutions or variations will fall within the scope of protection of the present application.

Claims

1. Flame retardant, antibacterial and sound insulation composite fiberboard, characterized in that: It is composed of a sound insulation and flame retardant layer, a reinforcement layer, an antibacterial and flame retardant layer and a finishing layer in sequence; The sound insulation and flame retardant layer is made by hot-melt bonding of sisal fiber, polyester fiber and collagen fiber and then adding a first flame retardant to mix; The reinforcing layer is a mesh structure made by hot-melt bonding of aramid fiber and bamboo fiber. The antibacterial flame retardant layer is made by hot pressing a mixture of raw materials including bamboo charcoal activated carbon, a second flame retardant and volcanic rock particles; The facing layer is a non-woven fabric surface layer; The sound insulation and flame retardant layer, the reinforcement layer, the antibacterial and flame retardant layer and the finishing layer are bonded by adding PMMA powder, hot baking and pressing; The average particle size of the PMMA powder does not exceed 6.5 μm; Preparation of the antibacterial flame retardant layer: adding the bamboo charcoal activated carbon and the second flame retardant to the silane coupling agent aqueous solution, ultrasonicating and stirring to prepare a suspension; adding carboxymethyl cellulose to the suspension to prepare a slurry, and then drying and grinding to prepare a composite powder; weighing 30-40 parts by weight of volcanic rock particles, 30-40 parts by weight of clay, 4-8 parts by weight of pore-forming agent, and 35-50 parts by weight of the composite powder, mixing them evenly, adding 25-35 parts by weight of water, granulating, and preparing particles; adding soy protein adhesive and mixing, placing the mixture in a hot press, and hot pressing at 500-700° C. to prepare the antibacterial flame retardant layer; The pore-forming agent is a mixture of ammonium bicarbonate and starch in a weight ratio of 3:1; The weight ratio of the bamboo charcoal activated carbon to the second flame retardant is (1-6):1; The average particle size of the bamboo charcoal activated carbon is 1-20 mm; The average particle size of the volcanic rock particles is 1-2 mm; The second flame retardant is composed of fumed silica and Fe3O4 powder in a weight ratio of 1:(1-3); The average particle size of the fumed silica is 25-35 nm.

2. The flame retardant, antibacterial and sound insulating composite fiberboard according to claim 1, characterized in that: The thickness ratio of the sound insulation and flame retardant layer, the reinforcement layer, the antibacterial and flame retardant layer and the finishing layer is: (3-5):(2-3):(1-3):

1.

3. The flame retardant, antibacterial and sound insulating composite fiberboard according to claim 1, characterized in that: The first flame retardant is a phosphate flame retardant.

4. The flame retardant, antibacterial and sound insulating composite fiberboard according to claim 1, characterized in that: The antibacterial and flame-retardant layer also contains natural plant ingredients.

5. The method for preparing the flame-retardant, antibacterial and sound-insulating composite fiberboard according to any one of claims 1 to 4, characterized in that: The following steps are involved: S1. Prepare the sound insulation and flame retardant layer, the reinforcement layer, the antibacterial and flame retardant layer and the finishing layer respectively; S2. The sound insulation and flame retardant layer, the reinforcement layer, the antibacterial and flame retardant layer and the finishing layer are stacked in order, PMMA powder is evenly sprinkled on the contact surface of each layer during stacking, pre-pressed, and the upper and lower surfaces are heated in a drying room by hot air jetting, and then cold rolled, cooled and consolidated after leaving the drying room; Among them, the preparation of the sound insulation and flame retardant layer: the sisal fiber and the polyester fiber are combed into a thinner fiber web by a carding machine, and then the web is laid by a cross-lapping machine and flattened by a press to form a randomly arranged sisal polyester fiber web layer of a certain thickness, and the collagen fibers are randomly laid on the sisal polyester fiber web layer to form a composite fiber web layer, and the composite fiber web layer is sent to a needle punching unit for needle punching, and all the collagen fibers are inserted into the interior of the sisal polyester fiber web layer. After hot-melt bonding and hot rolling, the first flame retardant is used for flame retardant finishing to obtain the sound insulation and flame retardant layer.

6. The method for preparing the flame-retardant, antibacterial and sound-insulating composite fiberboard according to claim 5, characterized in that: The reinforcement layer is prepared by combing and laying bamboo fibers to form a bamboo fiber mesh layer, combing and laying aramid fibers to form an aramid fiber mesh layer, and then respectively compounding the upper and lower surfaces of the bamboo fiber mesh layer with a layer of aramid fiber mesh layer, using a front and back needle-punching method to pierce all the aramid fibers of the aramid fiber mesh layer into the interior of the bamboo fiber mesh layer to obtain a bamboo fiber aramid fiber composite mesh layer, and then evenly sprinkling 3-5% of the weight of the bamboo fiber aramid fiber composite mesh layer on the upper surface of the bamboo fiber aramid fiber composite mesh layer. Finally, hot air penetration hot melt bonding is used for consolidation.

7. The method for preparing the flame-retardant, antibacterial and sound-insulating composite fiberboard according to claim 5, characterized in that: The finishing layer is prepared by spinning polypropylene fibers into a web, and then hot-rolling and bonding the web to obtain the finishing layer.

8. The method for preparing the flame-retardant, antibacterial and sound-insulating composite fiberboard according to claim 5, characterized in that: The temperature of the heat drying in step S2 is 110-170° C., and / or the time of the heat drying in step S2 is 1-3 hours.

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