Flame-retardant sound-insulation noise-reduction antibacterial non-woven felt and preparation method thereof

Abstract

The invention discloses a flame-retardant sound-insulation noise-reduction antibacterial non-woven felt and a preparation method thereof, and relates to the technical field of automotive interior products, the flame-retardant sound-insulation noise-reduction antibacterial non-woven felt comprises a non-woven felt body, the non-woven felt body further comprises a base material layer and an antibacterial layer arranged in the base material layer, the base material layer is composed of flame-retardant polyester staple fibers, the antibacterial layer is composed of an inorganic antibacterial material, and the inorganic antibacterial material is made of flame-retardant polyester staple fibers. The preparation method further comprises the step that the base material layer with the formed antibacterial layer is mixed with 30%-80% of polyester staple fibers and yarn, and the non-woven felt body is prepared through the non-woven technology of needling and / or spunlace and spunbond. According to the invention, regenerated polyester is adopted as a raw material, so that the polyester material is regenerated and recycled, the environment-friendly effect is realized, the industrial chain cost can be greatly reduced, a hollow structure can be manufactured, and the functions of heat insulation, sound insulation and noise reduction can be effectively realized; inorganic antibacterial powder such as nano-zinc oxide, nano-silver and nano-titanium dioxide is loaded in the hollow structure, so that adhesion growth of bacteria and molds can be effectively inhibited, and the service life of the product is effectively prolonged.

Description

Technical Field

[0001] The invention relates to the technical field of automobile interior decoration products, and in particular to a flame retardant, sound insulating, noise reducing and antibacterial non-woven felt and a preparation method thereof. Background Art

[0002] With the continuous improvement of social living standards, cars have entered thousands of households. Consumers' demand for car interiors has been continuously increasing, from a means of transportation to a comfortable and free mobile third space. In addition to conventional performance such as mechanical performance and driving performance, car interior comfort has also become an important performance that consumers value when choosing cars. As the auto part that can be most felt by consumers, the noise perception during driving is an important indicator affecting car sales and recognition.

[0003] At present, conventional sound insulation technology uses chemical fiber, flax, rubber, etc. as the main materials, which are processed and bonded to make elastic felt pads, which are used to buffer mechanical vibrations, damp and reduce shock, etc. However, they cannot eliminate or reduce the noise generated by vehicles such as cars during use. The noise is easily transmitted to consumers and causes discomfort. For this reason, we provide a flame retardant, sound insulation, noise reduction, and antibacterial non-woven felt and a preparation method thereof. Summary of the invention

[0004] The object of the present invention is to provide a flame retardant, sound insulating, noise reducing and antibacterial non-woven felt to solve the problems raised in the above background technology.

[0005] To achieve the above-mentioned objectives, the present invention provides the following technical solutions: a flame-retardant, sound-insulating, noise-reducing and antibacterial non-woven felt, comprising a non-woven felt body, the non-woven felt body also comprising a substrate layer and an antibacterial layer arranged inside the substrate layer, the substrate layer is composed of flame-retardant polyester staple fibers, and the antibacterial layer is composed of inorganic antibacterial materials, and a hollow structure is provided inside the substrate layer for depositing the antibacterial layer.

[0006] Preferably, the substrate layer is composed of a mixture of flame-retardant polyester staple fibers, polyester staple fibers and yarns, and the mixing ratio of the flame-retardant polyester staple fibers to the polyester staple fibers and yarns is 30%-80%.

[0007] Preferably, the flame retardant polyester staple fiber is composed of recycled polyester blended with a flame retardant.

[0008] Preferably, the recycled polyester is waste polyester fabric, and the flame-retardant polyester staple fiber has a fineness range of 1.5D-25D and a length range of 32-190mm.

[0009] Preferably, the antibacterial layer is any one of nano silver, zinc oxide and titanium oxide.

[0010] Preferably, the flame retardant is a phosphorus-nitrogen flame retardant, and the nitrogen-phosphorus flame retardant is composed of at least one of polyphosphate, organic zinc hypophosphite, polyphenylene sulfide, montmorillonite, silicon oxide, organic aluminum, and diphenyl phosphate.

[0011] Preferably, openings are arranged at equal intervals on the substrate layer, a connecting layer is arranged around the outer side of the substrate layer, the connecting layer is sequentially penetrated with openings and arranged in close proximity to the substrate layer, and the non-woven felt body is composed of the substrate layer and the connecting layer which are intermittently folded in half and then stacked in the same direction.

[0012] Preferably, the connecting layer is made of nylon material and is arranged in a honeycomb shape.

[0013] A method for preparing a flame-retardant, sound-insulating, noise-reducing and antibacterial non-woven felt comprises the following steps:

[0014] S1: Preparation of flame-retardant recycled polyester fiber: waste polyester fabrics are selected, sorted, cleaned, dried, and then melt-granulated, and then phosphorus and nitrogen flame retardants are added to blend for flame retardant modification to make flame-retardant polyester staple fibers for standby use.

[0015] S2: Forming of the substrate layer. The flame-retardant polyester staple fibers in step S1 are selected and spun by a melt-blown machine to form a substrate layer. A fluffy hollow structure is formed during the spinning process to complete the preparation of the substrate layer.

[0016] S3: Forming of the antibacterial layer: selecting the substrate layer in step S2, and loading the inorganic antibacterial material in the hollow structure by a hydrothermal method to form the antibacterial layer.

[0017] S4: Preparation of the non-woven felt body, the base material layer with the antibacterial layer formed in step S3 is mixed with 30%-80% of polyester staple fibers and yarns, and the non-woven process is performed by needle punching and / or spunlace, spunbonding to form the non-woven felt body.

[0018] Preferably, the preparation of the nonwoven felt body in the above step S4 further comprises the following steps:

[0019] Step 1: Preparation of the connecting layer: use nylon yarn to knit a honeycomb-shaped connecting layer for later use.

[0020] Step 2: Preparation of the non-woven felt body: select the non-woven felt body in step S4, cut openings arranged parallel to the width direction at equal intervals along its length direction, and set aside.

[0021] Step 3: Forming of the non-woven felt body, selecting the connecting layer in step 1 to sequentially penetrate the openings on the non-woven felt body in step 2, and folding the non-woven felt body and the connecting layer in half along the opening as the folding line to form a double-layer non-woven felt with intervals, the interval length being 3 times the distance between two adjacent openings, and using an ultrasonic welding machine to ultrasonically weld the connecting layer at the opening to fix it, and after fixing, smoothing the above-mentioned double-layer non-woven felt in the same direction and gluing or knitting to form a non-woven felt body with a continuous three-layer structure.

[0022] Compared with the prior art, the invention has the following beneficial effects: the flame-retardant, sound-insulating, noise-reducing and antibacterial non-woven felt uses recycled polyester as raw material, realizes the recycling of polyester materials, is environmentally friendly, and can significantly reduce the cost of the industrial chain; the use of short fibers produced by blending flame retardants can broaden the application scope of flame-retardant polyester fibers; the hollow structure is made to effectively perform the functions of heat insulation, sound insulation and noise reduction; inorganic antibacterial powders such as nano zinc oxide, nano silver, and nano titanium dioxide are loaded in the hollow structure to effectively inhibit the attachment and growth of bacteria and molds, effectively prolong the service life of the product, and at the same time, during use, the air purification will not It does not produce any odor, which meets the OEM's quality control requirements for the overall odor; the weaving structure is single and does not require layer-by-layer processing such as composite processing to achieve the application of composite functions. Furthermore, through the improved use of special connecting layers and special folding methods, the three-layer stacking of non-woven felt can be achieved through simple improvements as needed, and the flame retardant, sound insulation and noise reduction effects will be further improved. The honeycomb nylon connecting layer can not only improve the overall tensile strength of the non-woven felt, but also increase the wear resistance of the non-woven felt surface, which is not easy to pilling, and the connecting layer is used to improve the stability of the deposited antibacterial layer, which is not easy to migrate or fail the antibacterial layer. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] Figure 1 This is a schematic diagram of the cross-sectional structure of the nonwoven felt body of Example 1 of the present invention;

[0024] Figure 2 It is a schematic diagram of the top view of the opening portion of the non-woven felt body in the preparation stage of Example 4 of the present invention;

[0025] Figure 3 It is a schematic diagram of the top view of the structure of the non-woven felt body in the preparation stage of Example 4 of the present invention when the connecting layer is inserted;

[0026] Figure 4 This is a schematic diagram of the side structure of the non-woven felt body of Example 4 of the present invention.

[0027] In the figure: 1. non-woven felt body; 2. antibacterial layer; 3. substrate layer; 4. opening; 5. connecting layer. DETAILED DESCRIPTION

[0028] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0029] Example 1

[0030] See also Figure 1 A flame retardant, sound insulation, noise reduction and antibacterial non-woven felt comprises a non-woven felt body 1, wherein the non-woven felt body 1 further comprises a substrate layer 3 and an antibacterial layer 2 arranged inside the substrate layer 3. In the present embodiment, the substrate layer 3 may be composed of flame retardant polyester staple fibers, or the substrate layer 3 may be composed of a mixture of flame retardant polyester staple fibers, polyester staple fibers and yarns, and the mixing ratio of flame retardant polyester staple fibers to polyester staple fibers and yarns is 30%. The flame retardant polyester staple fibers are composed of recycled polyester blended with flame retardants, the recycled polyester is waste polyester fabric, and the waste polyester fabric is recycled polyester fabric melted into recycled polyester. The fineness range of the flame retardant polyester staple fibers is 1.5D; the length range is 32mm. The flame retardant is a phosphorus-nitrogen flame retardant, and the nitrogen-phosphorus flame retardant is composed of at least one of polyphosphate, organic zinc hypophosphite, polyphenylene sulfide, montmorillonite, silicon oxide, organic aluminum and diphenyl phosphate.

[0031] The substrate layer 3 has a hollow structure inside for depositing the antibacterial layer 2 . The antibacterial layer 2 is composed of an inorganic antibacterial material, and the antibacterial layer 2 is nanosilver.

[0032] A method for preparing a flame-retardant, sound-insulating, noise-reducing and antibacterial non-woven felt comprises the following steps:

[0033] S1: Preparation of flame-retardant recycled polyester fiber: waste polyester fabrics are selected, sorted, cleaned, dried, and then melt-granulated, and then phosphorus and nitrogen flame retardants are added to blend for flame retardant modification to make flame-retardant polyester staple fibers for standby use.

[0034] S2: Forming of the substrate layer. The flame-retardant polyester staple fibers in step S1 are selected and spun by a melt-blown machine to form a substrate layer. A fluffy hollow structure is formed during the spinning process to complete the preparation of the substrate layer.

[0035] S3: Forming of the antibacterial layer: selecting the substrate layer in step S2, and loading the inorganic antibacterial material in the hollow structure by a hydrothermal method to form the antibacterial layer.

[0036] S4: Preparation of the non-woven felt body, the base material layer with the antibacterial layer formed in step S3 is mixed with 30%-80% of polyester staple fibers and yarns, and the non-woven process is performed by needle punching and / or spunlace, spunbonding to form the non-woven felt body.

[0037] The mixed polyester staple fiber raw materials are made into felt pads through non-woven processes such as needle punching, spunlace, and spunbond, and are used as thermal insulation, noise reduction, and vibration reduction materials. They are widely used in decorative materials, automotive interior materials, sofa fabrics, aviation seats, high-speed rail cushions, carpets, foot mats, and other fields.

[0038] Example 2

[0039] The difference between this embodiment and the above-mentioned embodiment 1 is that the recycled polyester is made from plastic bottle flakes (discarded PET bottle flakes) melt-recycled polyester blended with phosphorus and nitrogen flame retardants to become flame-retardant recycled polyester fibers. Secondly, the antibacterial layer 2 is zinc oxide, and the mixing ratio of the flame-retardant polyester staple fiber to the polyester staple fiber and the yarn is 50%. Finally, the fineness range of the flame-retardant polyester staple fiber is 10D; the length range is 100mm.

[0040] Example 3

[0041] The difference between this embodiment and the above-mentioned embodiment 1 is that firstly, the antibacterial layer 2 uses titanium oxide, the mixing ratio of the flame retardant polyester staple fiber to the polyester staple fiber and the yarn is 80%, and the fineness of the flame retardant polyester staple fiber is 25D; and the length is 190 mm.

[0042] Example 4

[0043] See also Figure 2-4 The difference between this embodiment and the above-mentioned embodiments 1-3 is that, in order to improve the flame retardant, antibacterial, sound insulation and noise reduction effects of the product as a whole, openings 4 are arranged at equal intervals on the substrate layer 3, and a connecting layer 5 is arranged around the outer side of the substrate layer 3. The connecting layer 5 is penetrated with openings 4 in sequence and arranged in close contact with the substrate layer 3, and the non-woven felt body 1 is composed of the substrate layer 3 and the connecting layer 5 which are intermittently folded in half and then stacked in the same direction. The folding spacing is 3 times the spacing between two adjacent openings 4. Taking the openings arranged in sequence as 1, 2, 3, 4... as an example, when the opening 4 at position 3 is a folding line, the next intermittent folding line position is 6, and so on. The connecting layer 5 is made of nylon material, and the connecting layer 5 is arranged in a honeycomb shape.

[0044] Furthermore, the preparation of the non-woven felt body in the above step S4 further includes the following steps:

[0045] Step 1: Preparation of the connecting layer: use nylon yarn to knit a honeycomb-shaped connecting layer for later use.

[0046] Step 2: Preparation of the non-woven felt body: select the non-woven felt body in step S4, cut openings arranged parallel to the width direction at equal intervals along its length direction, and set aside.

[0047] Step 3: Forming of the non-woven felt body, selecting the connecting layer in step 1 to sequentially penetrate the openings on the non-woven felt body in step 2, and folding the non-woven felt body and the connecting layer in half along the opening as the folding line to form a double-layer non-woven felt with intervals, the interval length being 3 times the distance between two adjacent openings, and using an ultrasonic welding machine to ultrasonically weld the connecting layer at the opening to fix it, and after fixing, smoothing the above-mentioned double-layer non-woven felt in the same direction and gluing or knitting to form a non-woven felt body with a continuous three-layer structure.

[0048] It will be apparent to those skilled in the art that the invention is not limited to the details of the exemplary embodiments described above and that the invention can be implemented in other specific forms without departing from the spirit or essential features of the invention. Therefore, the embodiments should be considered exemplary and non-limiting in all respects, and the scope of the invention is defined by the appended claims rather than the foregoing description, and it is intended that all variations falling within the meaning and scope of the equivalent elements of the claims be included in the invention. Any reference numeral in a claim should not be considered as limiting the claim to which it relates.

Claims

1. A flame retardant, sound insulation, noise reduction and antibacterial non-woven felt, characterized by: The nonwoven felt body (1) comprises a substrate layer (3) and an antibacterial layer (2) arranged inside the substrate layer (3); the substrate layer (3) is composed of flame-retardant polyester staple fibers, and the antibacterial layer (2) is composed of an inorganic antibacterial material; a hollow structure for depositing the antibacterial layer (2) is provided inside the substrate layer (3).

2. The flame retardant, sound insulation, noise reduction and antibacterial non-woven felt according to claim 1, characterized in that: The substrate layer (3) is composed of a mixture of flame-retardant polyester staple fibers, polyester staple fibers and yarns, and the mixing ratio of the flame-retardant polyester staple fibers to the polyester staple fibers and yarns is 30%-80%.

3. The flame retardant, sound insulation, noise reduction and antibacterial non-woven felt according to claim 2, characterized in that: The flame retardant polyester staple fiber is composed of recycled polyester blended with a flame retardant.

4. The flame retardant, sound insulation, noise reduction and antibacterial non-woven felt according to claim 3, characterized in that: The recycled polyester is waste polyester fabric, and the flame-retardant polyester staple fiber has a fineness range of 1.5D-25D and a length range of 32-190mm.

5. The flame retardant, sound insulation, noise reduction and antibacterial non-woven felt according to claim 4, characterized in that: The antibacterial layer (2) is any one of nano silver, zinc oxide and titanium oxide.

6. The flame retardant, sound insulation, noise reduction and antibacterial nonwoven felt according to claim 5, characterized in that: The flame retardant is a phosphorus-nitrogen flame retardant, and the nitrogen-phosphorus flame retardant is composed of at least one of polyphosphate, organic zinc hypophosphite, polyphenylene sulfide, montmorillonite, silicon oxide, organic aluminum, and diphenyl phosphate.

7. The flame retardant, sound insulation, noise reduction and antibacterial nonwoven felt according to claim 1, characterized in that: The base material layer (3) is provided with openings (4) at equal intervals, a connecting layer (5) is arranged around the outer side of the base material layer (3), the connecting layer (5) is sequentially penetrated with the openings (4) and is arranged in close contact with the base material layer (3), and the non-woven felt body (1) is composed of the base material layer (3) and the connecting layer (5) which are intermittently folded in half and then stacked in the same direction.

8. The flame retardant, sound insulation, noise reduction and antibacterial nonwoven felt according to claim 7, characterized in that: The connecting layer (5) is made of nylon material, and the connecting layer (5) is arranged in a honeycomb shape.

9. A method for preparing the flame-retardant, sound-insulating, noise-reducing and antibacterial nonwoven felt according to any one of claims 1 to 8, characterized in that: The steps include: S1: Preparation of flame-retardant recycled polyester fiber: waste polyester fabric is selected, sorted, cleaned, dried, and then melt-granulated, and then phosphorus and nitrogen flame retardants are added to blend for flame retardant modification to make flame-retardant polyester staple fiber for standby use; S2: Forming of the substrate layer, selecting the flame-retardant polyester staple fibers in step S1 and spinning them through a melt-blown machine to form a substrate layer, and forming a fluffy hollow structure during the spinning process, thereby completing the preparation of the substrate layer; S3: Forming the antibacterial layer, selecting the substrate layer in step S2, and loading an inorganic antibacterial material in the hollow structure by a hydrothermal method to form an antibacterial layer; S4: Preparation of the non-woven felt body, the base material layer with the antibacterial layer formed in step S3 is mixed with 30%-80% of polyester staple fibers and yarns, and the non-woven process is performed by needle punching and / or spunlace, spunbonding to form the non-woven felt body.

10. The preparation method according to claim 9, characterized in that: The preparation of the nonwoven felt body in the above step S4 further includes the following steps: Step 1: Preparation of the connecting layer: knitting a honeycomb-shaped connecting layer with nylon yarn for later use; Step 2: preparing the non-woven felt body, selecting the non-woven felt body in step S4, cutting openings arranged parallel to the width direction at equal intervals along the length direction thereof, and setting them aside; Step 3: Forming of the non-woven felt body, selecting the connecting layer in step 1 to sequentially penetrate the openings on the non-woven felt body in step 2, and folding the non-woven felt body and the connecting layer in half along the opening as the folding line to form a double-layer non-woven felt with intervals, the interval length being 3 times the distance between two adjacent openings, and using an ultrasonic welding machine to ultrasonically weld the connecting layer at the opening to fix it, and after fixing, smoothing the above-mentioned double-layer non-woven felt in the same direction and gluing or knitting to form a non-woven felt body with a continuous three-layer structure.

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