Flame-retardant soundproofing noise-reducing antibacterial non-woven felt and preparation method thereof

Abstract

The application discloses a kind of flame-retardant sound insulation noise reduction antibacterial non-woven felt and preparation method thereof, it is related to automotive interior product technical field, including non-woven felt body, the non-woven felt body also includes substrate layer and is arranged in the antibacterial layer of substrate layer, the substrate layer is made of flame-retardant polyester staple fiber, and antibacterial layer is made of inorganic antibacterial material, preparation method also includes the substrate layer that is formed with antibacterial layer is mixed 30% with 80% polyester staple fiber and yarn is made into non-woven felt body by needle punching and / or water jet, spunlaid non-woven process of sticking.This application uses regenerated polyester as raw material, realizes the regeneration and recycling of polyester material, is friendly to environment, and can substantially reduce the cost of industry chain, make hollow structure, can effectively heat insulation sound insulation noise reduction function;Load inorganic antibacterial powder such as nano zinc oxide, nano silver, nano titanium dioxide in hollow structure, can effectively inhibit the adhesion growth of bacteria, mould, effectively prolong the service life of product.

Description

Technical Field

[0001] This invention relates to the field of automotive interior product technology, specifically to a flame-retardant, sound-insulating, noise-reducing, and antibacterial nonwoven felt and its preparation method. Background Technology

[0002] As living standards continue to improve, cars have become a common sight in many households. Consumers have transformed cars from mere means of transportation into comfortable and relaxing mobile third spaces. Their demands for car interiors are constantly increasing. In addition to conventional performance such as mechanical and driving performance, interior comfort has become an important factor for consumers when choosing a car. As the most perceptible car component, noise levels during driving are a crucial indicator affecting car sales and acceptance.

[0003] Currently, conventional sound insulation technologies use chemical fibers, flax, rubber, etc. as the main materials, which are processed and bonded to make elastic felt pads. These are used for buffering mechanical vibrations and damping shock absorption, but they cannot eliminate or reduce the noise generated by vehicles such as cars during use. Noise is easily transmitted to consumers and causes discomfort. Therefore, we provide a flame-retardant, sound-insulating, noise-reducing, and antibacterial non-woven felt and its preparation method. Summary of the Invention

[0004] The purpose of this invention is to provide a flame-retardant, sound-insulating, noise-reducing, and antibacterial nonwoven felt to solve the problems mentioned in the background art.

[0005] To achieve the above objectives, the present invention provides the following technical solution: a flame-retardant, sound-insulating, noise-reducing, and antibacterial nonwoven felt, comprising a nonwoven felt body, wherein the nonwoven felt body further comprises a substrate layer and an antibacterial layer disposed inside the substrate layer, wherein the substrate layer is composed of flame-retardant polyester short fibers, and the antibacterial layer is composed of inorganic antibacterial materials, wherein the interior of the substrate layer is provided with a hollow structure for the deposition of the antibacterial layer.

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

[0007] Preferably, the flame-retardant polyester staple fiber is composed of a recycled polyester blend 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 phosphorus-nitrogen flame retardant is composed of at least one of polyphosphate, organic zinc hypophosphite, polyphenylene sulfide, montmorillonite, silicon dioxide, organoaluminum, and diphenyl phosphate.

[0011] Preferably, the substrate layer has openings at equal intervals, and a connecting layer is wrapped around the outside of the substrate layer. The connecting layer passes through the openings in sequence and is arranged to fit the substrate layer. The nonwoven felt body is composed of the substrate layer and the connecting layer, which are intermittently folded and stacked in the same direction.

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

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

[0014] S1: Preparation of flame-retardant recycled polyester fiber: Waste polyester fabrics are selected, sorted, cleaned, dried, melt-granulated, and then mixed with phosphorus and nitrogen flame retardants for flame-retardant modification to produce flame-retardant polyester staple fiber for later use.

[0015] S2: Forming of the substrate layer: The flame-retardant polyester staple fiber selected in step S1 is spun into a substrate layer by a meltblown machine, and a fluffy hollow structure is formed during the spinning process, thus completing the preparation of the substrate layer.

[0016] S3: Forming of the antibacterial layer: Select the substrate layer from step S2, and load inorganic antibacterial materials into the hollow structure using a hydrothermal method to form the antibacterial layer.

[0017] S4: Preparation of the nonwoven felt body: The nonwoven felt body is made by mixing 30%-80% of polyester staple fiber and yarn with the substrate layer with antibacterial layer formed in step S3, and then processing it through needle punching and / or hydroentangling and spunbonding nonwoven processes.

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

[0019] Step 1: Preparation of the connecting layer. A honeycomb-shaped connecting layer is knitted from nylon yarn and set aside.

[0020] Step 2: Preparation of the non-woven felt body. Select the non-woven felt body from step S4 and cut openings parallel to the width direction at equal intervals along its length for later use.

[0021] Step 3: Forming the nonwoven felt body. The connecting layer from Step 1 is sequentially threaded through the openings on the nonwoven felt body from Step 2. The nonwoven felt body and the connecting layer are folded at intervals along the openings to form a double-layered nonwoven felt with intervals of 3 times the distance between two adjacent openings. The connecting layer at the openings is ultrasonically welded and fixed using an ultrasonic welding machine. After fixing, the double-layered nonwoven felt with intervals is smoothed in the same direction and then glued or knitted to form a nonwoven felt body with a continuous three-layer structure.

[0022] Compared with existing technologies, the beneficial effects of this invention are as follows: This flame-retardant, sound-insulating, noise-reducing, and antibacterial nonwoven felt uses recycled polyester as raw material, realizing the recycling of polyester materials, which is environmentally friendly and can significantly reduce the cost of the industrial chain. The use of short fibers produced by blending flame-retardant fibers broadens the application scope of flame-retardant polyester fibers. The hollow structure effectively provides heat insulation, sound insulation, and noise reduction. Loading inorganic antibacterial powders such as nano-zinc oxide, nano-silver, and nano-titanium dioxide into the hollow structure effectively inhibits the adhesion and growth of bacteria and mold, effectively extending the product's service life. Simultaneously, during use, it purifies the air without... It produces no odor, meeting the overall odor quality control requirements of the OEM; the simple weaving structure eliminates the need for multiple layers of processing, enabling the application of composite functions. Furthermore, through the improved use of a special connecting layer and a special folding method, three layers of non-woven felt can be stacked as needed with simple modifications, further enhancing flame retardancy, sound insulation, and noise reduction effects. The honeycomb nylon connecting layer not only improves the overall tensile strength of the non-woven felt but also increases the abrasion resistance coefficient of the non-woven felt surface, making it less prone to pilling. The connecting layer also improves the stability of the deposited antibacterial layer, making it less prone to migration and failure. Attached Figure Description

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

[0024] Figure 2 This is a top view of the opening portion during the preparation stage of the nonwoven felt body in Embodiment 4 of the present invention.

[0025] Figure 3 This is a top view of the nonwoven felt body preparation stage of the present invention, showing the connection layer being installed. (This is a schematic diagram of the structure in the state of the connection layer being installed during the preparation stage of the nonwoven felt body in Embodiment 4 of the present invention.)

[0026] Figure 4 This is a schematic diagram of the side structure of the nonwoven felt body in Embodiment 4 of the present invention.

[0027] In the diagram: 1. Non-woven felt body; 2. Antibacterial layer; 3. Substrate layer; 4. Opening; 5. Connecting layer. Detailed Implementation

[0028] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0029] Example 1

[0030] Please see Figure 1 A flame-retardant, sound-insulating, noise-reducing, and antibacterial nonwoven felt includes a nonwoven felt body 1, which further includes a substrate layer 3 and an antibacterial layer 2 disposed inside the substrate layer 3. In this embodiment, the substrate layer 3 can be composed of flame-retardant polyester staple fibers, or it can be composed of a mixture of flame-retardant polyester staple fibers, polyester staple fibers, and yarn, with a mixing ratio of 30% for the flame-retardant polyester staple fibers and polyester staple fibers and yarn. The flame-retardant polyester staple fibers are composed of recycled polyester blended with flame retardants. The recycled polyester is waste polyester fabric, which is recycled polyester fabric melted into recycled polyester. The flame-retardant polyester staple fibers have a fineness range of 1.5D and a length range of 32mm. The flame retardant is a phosphorus-nitrogen flame retardant, which is composed of at least one of polyphosphate, organic zinc hypophosphite, polyphenylene sulfide, montmorillonite, silica, organic aluminum, and diphenyl phosphate.

[0031] The substrate layer 3 has a hollow structure inside for the deposition of the antibacterial layer 2. The antibacterial layer 2 is composed of inorganic antibacterial materials and is made of nano-silver.

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

[0033] S1: Preparation of flame-retardant recycled polyester fiber: Waste polyester fabrics are selected, sorted, cleaned, dried, melt-granulated, and then mixed with phosphorus and nitrogen flame retardants for flame-retardant modification to produce flame-retardant polyester staple fiber for later use.

[0034] S2: Forming of the substrate layer: The flame-retardant polyester staple fiber selected in step S1 is spun into a substrate layer by a meltblown machine, and a fluffy hollow structure is formed during the spinning process, thus completing the preparation of the substrate layer.

[0035] S3: Forming of the antibacterial layer: Select the substrate layer from step S2, and load inorganic antibacterial materials into the hollow structure using a hydrothermal method to form the antibacterial layer.

[0036] S4: Preparation of the nonwoven felt body: The nonwoven felt body is made by mixing 30%-80% of polyester staple fiber and yarn with the substrate layer with antibacterial layer formed in step S3, and then processing it through needle punching and / or hydroentangling and spunbonding nonwoven processes.

[0037] The mixed polyester staple fiber raw materials are processed through nonwoven processes such as needle punching, hydroentangling, and spunbonding to make felt mats for use as heat insulation, noise reduction, and vibration damping materials. They are widely used in decorative materials, automotive interior materials, sofa fabrics, aircraft seats, high-speed rail mats, carpets, floor mats, and other fields.

[0038] Example 2

[0039] The difference between this embodiment and the above embodiment 1 is that the recycled polyester is made by melting recycled polyester from plastic bottle flakes (waste PET bottle flakes) and blending it with phosphorus and nitrogen flame retardants to form flame retardant recycled polyester fibers. Secondly, the antibacterial layer 2 is zinc oxide, and the mixing ratio of flame retardant polyester staple fiber with polyester staple fiber and 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 embodiment 1 is that, firstly, the antibacterial layer 2 is made of titanium dioxide, the mixing ratio of flame-retardant polyester staple fiber and polyester staple fiber and yarn is 80%, and the fineness of the flame-retardant polyester staple fiber is 25D; the length is 190mm.

[0042] Example 4

[0043] Please see Figure 2-4 The difference between this embodiment and embodiments 1-3 above is that, in order to improve the overall flame retardant, antibacterial, and sound insulation effects of the product, the substrate layer 3 is provided with openings 4 at equal intervals, and a connecting layer 5 is wrapped around the outside of the substrate layer 3. The connecting layer 5 is arranged with the openings 4 in sequence and attached to the substrate layer 3. The non-woven felt body 1 is composed of the substrate layer 3 and the connecting layer 5, which are intermittently folded and stacked in the same direction. The folding distance is 3 times the distance 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 the fold line, the next intermittent fold line position is 6, and so on. The connecting layer 5 is made of nylon material and is arranged in a honeycomb pattern.

[0044] Furthermore, the preparation of the nonwoven felt body in step S4 above also includes the following steps:

[0045] Step 1: Preparation of the connecting layer. A honeycomb-shaped connecting layer is knitted from nylon yarn and set aside.

[0046] Step 2: Preparation of the non-woven felt body. Select the non-woven felt body from step S4 and cut openings parallel to the width direction at equal intervals along its length for later use.

[0047] Step 3: Forming the nonwoven felt body. The connecting layer from Step 1 is sequentially threaded through the openings on the nonwoven felt body from Step 2. The nonwoven felt body and the connecting layer are folded at intervals along the openings to form a double-layered nonwoven felt with intervals of 3 times the distance between two adjacent openings. The connecting layer at the openings is ultrasonically welded and fixed using an ultrasonic welding machine. After fixing, the double-layered nonwoven felt with intervals is smoothed in the same direction and then glued or knitted to form a nonwoven felt body with a continuous three-layer structure.

[0048] It will be apparent to those skilled in the art that the present 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 its spirit or essential characteristics. Therefore, the embodiments should be considered in all respects as exemplary and non-limiting, and the scope of the invention is defined by the appended claims rather than the foregoing description. Thus, all variations falling within the meaning and scope of equivalents of the claims are intended to be included within the present invention. No reference numerals in the claims should be construed as limiting the scope of the claims.

Claims

1. A flame-retardant, sound-insulating, noise-reducing, and antibacterial nonwoven felt, characterized in that: The nonwoven felt body (1) includes a substrate layer (3) and an antibacterial layer (2) disposed inside the substrate layer (3). The substrate layer (3) is composed of flame-retardant polyester short fibers, and the antibacterial layer (2) is composed of inorganic antibacterial materials. The substrate layer (3) has a hollow structure inside for the deposition of the antibacterial layer (2). The substrate layer (3) has openings (4) at equal intervals. The substrate layer (3) is surrounded by a connecting layer (5). The connecting layer (5) passes through the openings (4) in sequence and is arranged to fit the substrate layer (3). The nonwoven felt body (1) is composed of the substrate layer (3) and the connecting layer (5) folded intermittently and stacked in the same direction. The connecting layer (5) is made of nylon material and is arranged in a honeycomb pattern.

2. The flame-retardant, sound-insulating, noise-reducing, and antibacterial nonwoven felt according to claim 1, characterized in that: The substrate layer (3) is composed of flame-retardant polyester staple fiber mixed with polyester staple fiber and yarn, and the mixing ratio of flame-retardant polyester staple fiber with polyester staple fiber and yarn is 30%-80%.

3. The flame-retardant, sound-insulating, noise-reducing, and antibacterial nonwoven felt according to claim 2, characterized in that: The flame-retardant polyester staple fiber is composed of recycled polyester blended with flame retardant.

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

7. A method for preparing a flame-retardant, sound-insulating, noise-reducing, and antibacterial nonwoven felt as described in any one of claims 1-6, characterized in that, Includes the following steps: S1: Preparation of flame-retardant recycled polyester fiber: waste polyester fabrics are selected, sorted, cleaned, dried and melt-granulated, then phosphorus and nitrogen flame retardants are added and blended for flame-retardant modification to produce flame-retardant polyester staple fiber for later use. S2: Forming of the substrate layer: The flame-retardant polyester staple fiber selected in step S1 is spun into a substrate layer by a meltblown machine, and a fluffy hollow structure is formed during the spinning process, thus completing the preparation of the substrate layer. S3: Forming of the antibacterial layer: Select the substrate layer from step S2, load inorganic antibacterial materials into the hollow structure using a hydrothermal method to form the antibacterial layer; S4: Preparation of the nonwoven felt body: The nonwoven felt body is made by mixing 30%-80% of polyester staple fiber and yarn with the substrate layer with antibacterial layer formed in step S3, and then processing it through needle punching and / or hydroentangling and spunbonding nonwoven processes.

8. The preparation method according to claim 7, characterized in that, The preparation of the nonwoven felt body in step S4 above also includes the following steps: Step 1: Preparation of the connecting layer: Select nylon yarn and knit it into a honeycomb-shaped connecting layer for later use; Step 2: Preparation of the non-woven felt body. Select the non-woven felt body from step S4 and cut openings parallel to the width direction at equal intervals along its length for later use. Step 3: Forming the nonwoven felt body. The connecting layer from Step 1 is sequentially threaded through the openings on the nonwoven felt body from Step 2. The nonwoven felt body and the connecting layer are folded at intervals along the openings to form a double-layered nonwoven felt with intervals of 3 times the distance between two adjacent openings. The connecting layer at the openings is ultrasonically welded and fixed using an ultrasonic welding machine. After fixing, the double-layered nonwoven felt with intervals is smoothed in the same direction and then glued or knitted to form a nonwoven felt body with a continuous three-layer structure.

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