High-flame-retardant high-temperature-resistant automotive interior leather and preparation method thereof

Abstract

The invention provides high-flame-retardant high-temperature-resistant automotive interior leather which comprises a polyolefin base material layer and a surface coating, the polyolefin base material layer comprises a mixture composed of 10-90 parts by weight of ethylene copolymer elastomer and 10-90 parts by weight of ethylene-propylene-diene monomer, and the sum of the parts by weight of the ethylene copolymer elastomer and the ethylene-propylene-diene monomer is 100; and 0.1-5 parts by weight of an assistant cross-linking agent, wherein the assistant cross-linking agent comprises a flame-retardant assistant cross-linking agent. The automotive trim leather provided by the invention has good mechanical properties, temperature resistance, high flame retardance, aging resistance, environmental protection and the like, and is simple in process and low in cost.

Description

Technical Field

[0001] The invention relates to the field of automobile interior leather, and in particular to a highly flame-retardant and high-temperature-resistant automobile interior leather and a preparation method thereof. Background Art

[0002] Automotive interior leather is mainly used in automotive seats, automotive door panels, automotive dashboards, etc. There are many types of automotive interior leather, such as polyvinyl chloride artificial leather (PVC artificial leather), thermoplastic polyolefin artificial leather (TPO artificial leather), polyurethane artificial leather (PU artificial leather), etc. With the continuous development of the automotive industry, automotive interior leather has very high material properties, and has strict requirements on temperature resistance, weather resistance, odor, flame retardancy, appearance, wear resistance, mechanics and environmental protection indicators.

[0003] In particular, artificial leathers with high flammability, such as polyolefin artificial leathers, are widely used, and therefore, flame retardants for imparting flame retardancy are inevitably blended into these artificial leathers. In addition, as flame retardant methods, it is well known that halogen flame retardants, inorganic phosphorus flame retardants composed of polyphosphate flame retardants such as red phosphorus or ammonium polyphosphate, organic phosphorus flame retardants represented by triaryl phosphate compounds, metal hydroxides, or antimony oxides and melamine compounds as flame retardant aids are used alone or in combination.

[0004] Among them, although halogen flame retardants have excellent flame retardant effects, they produce harmful substances such as hydrogen halide gas or dioxins when burned, so flame retardant methods that do not use halogen flame retardants are expected. In addition, metal hydroxides such as magnesium hydroxide cannot obtain flame retardancy when they are not mixed in large quantities, so there is a problem of reduced physical properties of molded products.

[0005] As phosphorus-based flame retardants, phosphate ester compounds that are excellent in flame retardancy for polycarbonate and the like, and inorganic phosphorus-based flame retardants that are excellent in flame retardancy for polyolefins have been used.

[0006] TPO used in automotive interior leather generally refers to a mixture of polyethylene, polypropylene, and elastomers, which is a rubber-plastic blended thermoplastic elastomer. Polyethylene and polypropylene are linear structures, and the elastomer has a certain degree of crosslinking, which is a bulk network structure. The elastomer is dispersed in the mixture of polyethylene and polypropylene in a granular state to form an island structure. The crosslinked bulk elastomer provides mechanical strength, heat resistance and aging resistance. The more crosslinking points the bulk elastomer provides, the higher the degree of crosslinking, and the better the mechanical properties, heat resistance and aging resistance. The degree of crosslinking in the automotive interior leather system cannot be too high, which makes the embossing poorly retainable. Therefore, TPO embossing usually requires a deep punching process, and the cost of replacing the mold is high.

[0007] Therefore, it is necessary to develop an automotive interior leather with good mechanics, aging resistance, environmental protection, high flame retardancy, good temperature resistance and easy processing. Summary of the invention

[0008] The invention provides a highly flame-retardant and high-temperature-resistant automobile interior leather, comprising a polyolefin substrate layer and a surface coating, wherein the polyolefin substrate layer comprises: a mixture of 10 to 90 parts by weight of an ethylene copolymer elastomer and 10 to 90 parts by weight of ethylene propylene diene monomer rubber, wherein the sum of the parts by weight of the ethylene copolymer elastomer and the ethylene propylene diene monomer rubber is 100 parts; and 0.1 to 5 parts by weight of a cross-linking aid. The cross-linking aid comprises a flame-retardant cross-linking aid.

[0009] Furthermore, the horizontal burning speed is less than 30 mm / min

[0010] Furthermore, the flame retardant co-crosslinking agent is selected from one or more of tetraphenyl bisphenol A diphosphate, bisphenol A bis(diphenyl) phosphate, aryl diphosphate, tetraphenyl m-phenol diphosphate, trimethyl diphenyl phosphate, alkane diaryl phosphonate, 2-ethylhexyl diphenyl phosphate, isodecyl diphenyl phosphate, tributyl phosphate, trioctyl phosphate, tributoxyethyl phosphate, dimethyl methyl phosphate, diethyl ethyl phosphate, and triaryl phosphonate.

[0011] Furthermore, the ethylene copolymer elastomer is copolymerized by ethylene and another monomer, and the other monomer is selected from one of alpha olefins with a carbon chain length of C4-C8 or vinyl acetate.

[0012] Furthermore, the other monomer is vinyl acetate, and the content of vinyl acetate in the ethylene copolymer elastomer is greater than 10 wt % and less than 40 wt %.

[0013] Furthermore, the other monomer is an alpha olefin with a carbon chain length of C4-C8.

[0014] Furthermore, the auxiliary cross-linking agent also includes one or more of triallyl isocyanurate, triallyl cyanurate, glycidyl (meth)acrylate, methyl (meth)acrylate, trimethylolpropane trimethacrylate, propoxylated glycerol triacrylate, 2-carboxyethyl acrylate, isobornyl (meth)acrylate, 2-hydroxyethyl methacrylate phosphate and tripropylene glycol acrylate.

[0015] Furthermore, the polyolefin substrate layer has a cross-linking degree of at least 40%, and the cross-linking method is electron beam irradiation cross-linking.

[0016] Furthermore, the polyolefin substrate layer further contains a phosphonate-based or hindered phenol-based antioxidant.

[0017] Furthermore, the polyolefin substrate layer further contains an inorganic metal oxide, preferably zinc oxide.

[0018] The present invention also proposes a method for preparing highly flame-retardant and high-temperature-resistant automobile interior leather, comprising the following steps:

[0019] (1) EPDM rubber, flame retardant co-crosslinking agent and peroxide are fully mixed and added into a granulator at a granulation temperature of 160 to 180° C., and granulated by the granulator to obtain mixture particles A;

[0020] (2) fully mixing the ethylene copolymer elastomer, the mixture particles A, the co-crosslinking agent, the antioxidant, the inorganic metal oxide and other additives to obtain a mixture B;

[0021] (3) adding the mixture B into an extruder at an extrusion temperature of 50 to 130° C., extruding through a T-shaped flat die to form a film, and winding to obtain a film material;

[0022] (4) irradiating the film obtained in step (3) with β rays or X rays, with an irradiation dose of 10 to 100 KGY;

[0023] (5) coating the film material irradiated in step (4), and obtaining a highly flame-retardant and high-temperature-resistant automotive interior leather after drying.

[0024] The present invention also proposes a method for preparing highly flame-retardant and high-temperature-resistant automobile interior leather, comprising the following steps:

[0025] (1) fully mixing EPDM rubber, ethylene copolymer elastomer, co-crosslinking agent, flame retardant co-crosslinking agent, antioxidant, inorganic metal oxide, and other additives to obtain a mixture B;

[0026] (2) adding the mixture B obtained in step (1) into an extruder at an extrusion temperature of 70 to 130° C., extruding and casting the mixture onto a fabric base fabric through a T-shaped flat die, and winding the mixture to obtain a film material;

[0027] (3) irradiating the film obtained in step (2) with β rays or X rays, with an irradiation dose of 10 to 100 KGY;

[0028] (4) coating the film material irradiated in step (3), and obtaining a highly flame-retardant and high-temperature-resistant automotive interior leather after drying.

[0029] The present invention also proposes a method for preparing highly flame-retardant and high-temperature-resistant automobile interior leather, comprising the following steps:

[0030] (1) EPDM rubber, flame retardant co-crosslinking agent and peroxide are fully mixed, added into a granulator, the granulation temperature is 160-180° C., and granulated by the granulator to obtain mixture particles A;

[0031] (2) fully mixing the ethylene copolymer elastomer, the mixture particles A, the co-crosslinking agent, the antioxidant, the inorganic metal oxide and other additives to obtain a mixture B;

[0032] (3) adding the mixture B obtained in step (2) into an extruder at an extrusion temperature of 70 to 130° C., and extruding and casting the mixture onto a fabric base fabric through a T-shaped flat die to obtain a polyolefin substrate layer;

[0033] (4) coating the polyolefin substrate layer obtained in step (3) and drying it to obtain a surface coating;

[0034] (5) embossing the polyolefin substrate layer having the surface coating obtained in step (4);

[0035] (6) The film obtained in step (5) is irradiated with β rays or X rays, with an irradiation dose of 10 to 100 KGY to obtain highly flame-retardant and high-temperature resistant automotive interior leather.

[0036] The present application includes at least one of the following beneficial technical effects:

[0037] 1. The automotive interior leather formula system provided by the present invention contains no flame retardant, but adds a small amount of flame retardant co-crosslinking agent, so the secondary pollution is small.

[0038] 2. The flame retardant properties of the automotive interior leather formula system provided by the present invention can be significantly improved by adding a flame retardant co-crosslinking agent.

[0039] 3. The automotive interior leather formula system provided by the present invention increases the crosslinking density and accelerates the crosslinking speed during the irradiation process by adding a flame retardant co-crosslinking agent. After irradiation crosslinking, a three-dimensional network structure is formed, thereby improving the mechanical strength and weather resistance required for the automotive interior leather.

[0040] 4. The present invention adopts ethylene copolymer elastomer and uncrosslinked EPDM rubber to blend and form, both of which are thermoplastic polyolefin elastomers with linear structure and easy processing. The extrusion or casting molding temperature is 50-130°C, the processing temperature is low and the processing window is wide.

[0041] 5. The present invention can selectively perform embossing after the film is formed. The film before cross-linking is a linear structure, which is easy to emboss. After embossing, the film is irradiated and cross-linked, and the film forms a body structure, which improves the embossing retention.

[0042] 6. The automotive interior leather provided in this application has good mechanical, temperature resistance, high flame retardancy, aging resistance, environmental protection and other properties, and has a simple process and low cost. DETAILED DESCRIPTION

[0043] In order to make the invention purpose, technical scheme and beneficial technical effect of the present invention clearer, the present invention is described in detail below in conjunction with specific embodiments. It should be understood that the embodiments described in this specification are only for explaining the present invention, not for limiting the present invention.

[0044] For simplicity, only some numerical ranges are explicitly disclosed herein. However, any lower limit can be combined with any upper limit to form an unambiguous range; and any lower limit can be combined with other lower limits to form an unambiguous range, and any upper limit can be combined with any other upper limit to form an unambiguous range. In addition, although not explicitly stated, each point or single value between the range endpoints is included in the range. Thus, each point or single value can be combined with any other point or single value as its own lower limit or upper limit or with other lower limits or upper limits to form an unambiguous range.

[0045] In the description of this article, it should be noted that, unless otherwise specified, “above” and “below” are inclusive of the number, and “multiple” in “one or more” means more than two.

[0046] The above summary of the invention of the present invention is not intended to describe each disclosed embodiment or each implementation in the present invention. The following description more specifically illustrates exemplary embodiments. In many places throughout the application, guidance is provided by a series of examples, which can be used in various combinations. In each embodiment, enumeration is only used as a representative group and should not be interpreted as exhaustive.

[0047] The invention provides a highly flame-retardant and high-temperature-resistant automobile interior leather, comprising a polyolefin substrate layer and a surface coating, wherein the polyolefin substrate layer comprises: a mixture of 10 to 90 parts by weight of an ethylene copolymer elastomer and 10 to 90 parts by weight of ethylene propylene diene monomer rubber, wherein the sum of the parts by weight of the ethylene copolymer elastomer and the ethylene propylene diene monomer rubber is 100 parts; and 0.1 to 5 parts by weight of a cross-linking aid. The cross-linking aid comprises a flame-retardant cross-linking aid.

[0048] The invention provides a highly flame-retardant and high-temperature-resistant automobile interior leather, the horizontal burning speed of which is less than 30 mm / min.

[0049] The invention provides a highly flame-retardant and high-temperature resistant automobile interior leather, wherein the flame-retardant auxiliary cross-linking agent is selected from one or more of tetraphenyl bisphenol A diphosphate, bisphenol A bis(diphenyl) phosphate, aryl diphosphate, tetraphenyl m-phenol diphosphate, trimethyl diphenyl phosphate, alkane diaryl phosphonate, 2-ethylhexyl diphenyl phosphate, isodecyl diphenyl phosphate, tributyl phosphate, trioctyl phosphate, tributoxyethyl phosphate, dimethyl methyl phosphate, diethyl ethyl phosphate, and triaryl phosphonate.

[0050] In the highly flame-retardant and high-temperature-resistant automotive interior leather of the present invention, the coating can adopt coating materials for leather known in the art, including one or more of polyurethane coatings, acrylates or silicone coatings. The automotive interior coating generally has suitable wear resistance, brightness and adhesion, etc., and those skilled in the art can select according to actual needs.

[0051] The automotive interior leather provided by the present invention uses polyolefin as a base material. Using polyolefin as a base material, the amount of odorous volatiles generated by polyolefin is very small. Compared with solvent-based PU automotive interior leather and PVC automotive interior leather added with plasticizer, the automotive interior leather produced by the present invention has lower odor, and the production process has better environmental protection performance, so as to meet occasions with higher odor and environmental protection requirements.

[0052] The ethylene copolymer elastomer of the polyolefin substrate layer is copolymerized by ethylene and another monomer, and the other monomer is selected from one of alpha olefins with a carbon chain length of C4-C8 or vinyl acetate.

[0053] Based on the influence of carbon chain length on polymer processing conditions and mechanical properties, alpha olefins with carbon chain lengths between C4 and C8 are selected as another monomer of ethylene copolymer elastomers. In the copolymer formed with ethylene, the larger the carbon chain length of the alpha olefin, the better the polymer softness, while the mechanical strengths such as folding resistance, tear strength, and tensile strength will decrease accordingly. Based on the balance of the above properties, C4-C8 alpha olefins are selected as another monomer of ethylene copolymer elastomers.

[0054] Vinyl acetate can also be selected as another monomer of the ethylene copolymer elastomer. The higher the content of vinyl acetate in the ethylene copolymer elastomer, the better the polymer fluidity and the higher the softness. The ester unit in the vinyl acetate structure can be used as a crosslinking point during the radiation crosslinking process to form a body structure. According to the performance requirements of automotive interior leather products, the vinyl acetate monomer content is selected to be in the range of 10-40% by mass in the ethylene copolymer elastomer.

[0055] The composition of the polyolefin substrate layer contains EPDM rubber, which can improve the processing performance and film-forming performance of the polyolefin substrate. EPDM rubber is a copolymer of ethylene, propylene and a third monomer, and the third monomer has a non-conjugated diene structure. The EPDM rubber contains carbon-carbon double bonds that can participate in the polymerization reaction, providing cross-linking active points for the radiation cross-linking reaction. Non-conjugated dienes include ethylidene norbornene, dicyclopentadiene, and 1,4-hexadiene, preferably ethylidene norbornene; using EPDM rubber with an appropriate non-conjugated diene content is helpful to improve the cross-linking density and cross-linking speed of the polyolefin substrate.

[0056] The polyolefin substrate layer also includes a crosslinking aid. The crosslinking aid can provide crosslinking active points for the radiation crosslinking reaction and can improve the crosslinking degree of the polyolefin layer. The amount of the crosslinking aid added can be adjusted according to actual conditions. In some embodiments, based on 100 parts by weight of the ethylene copolymer elastomer and the ethylene propylene diene monomer rubber, the polyolefin substrate layer also includes 0.1-5 parts of the crosslinking aid.

[0057] The flame retardant co-crosslinking agent can not only provide crosslinking active points for the radiation crosslinking reaction and improve the crosslinking degree of the polyolefin layer, but also play a flame retardant function.

[0058] The flame retardant cross-linking aid is selected from one or more of tetraphenyl bisphenol A diphosphate, bisphenol A bis(diphenyl) phosphate, aryl diphosphate, tetraphenyl m-phenol diphosphate, trimethyl diphenyl phosphate, alkane diaryl phosphonate, 2-ethylhexyl diphenyl phosphate, isodecyl diphenyl phosphate, tributyl phosphate, trioctyl phosphate, tributoxyethyl phosphate, dimethyl methyl phosphate, diethyl ethyl phosphate, and triaryl phosphonate.

[0059] Examples of auxiliary cross-linking agents also include triallyl isocyanurate, triallyl cyanurate, glycidyl (meth)acrylate, methyl (meth)acrylate, trimethylolpropane trimethacrylate, propoxylated glycerol triacrylate, 2-carboxyethyl acrylate, isobornyl (meth)acrylate, diallylamine, diallyl sulfide, N,N-dimethyl-bisacrylamide, ethylene glycol dimethacrylate, triallyl cyanurate, tetramethylolmethane tetraacrylate, 2-hydroxyethyl methacrylate phosphate, and one or more of tripropylene glycol acrylate.

[0060] The production process of the polyolefin substrate layer is extrusion molding or casting, and its processing technology is related to the melting point of the polymer.

[0061] The polyolefin substrate layer has a cross-linking degree greater than 40%, and the cross-linking method is electron beam irradiation cross-linking.

[0062] The polyolefin substrate layer may include a foamed layer.

[0063] The side of the polyolefin substrate layer facing away from the coating layer can be attached to the base fabric.

[0064] In some embodiments, the automotive interior leather may also selectively contain other additives, such as colorants, fillers, foaming agents, and the like.

[0065] In some embodiments, the automotive interior leather contains a phosphonate-based or hindered phenol-based antioxidant.

[0066] In some embodiments, the automotive interior leather contains an inorganic metal oxide, preferably zinc oxide.

[0067] The present invention also proposes a method for preparing highly flame-retardant and high-temperature-resistant automobile interior leather, comprising the following steps:

[0068] (1) EPDM rubber, flame retardant co-crosslinking agent and peroxide are fully mixed and added into a granulator at a granulation temperature of 160 to 180° C., and granulated by the granulator to obtain mixture particles A;

[0069] (2) fully mixing the ethylene copolymer elastomer, the mixture particles A, the co-crosslinking agent, the antioxidant, the inorganic metal oxide and other additives to obtain a mixture B;

[0070] (3) adding the mixture B into an extruder at an extrusion temperature of 50 to 130° C., extruding through a T-shaped flat die to form a film, and winding to obtain a film material;

[0071] (4) irradiating the film obtained in step (3) with β rays or X rays, with an irradiation dose of 10 to 100 KGY;

[0072] (5) coating the film material irradiated in step (4), and obtaining a highly flame-retardant and high-temperature-resistant automotive interior leather after drying.

[0073] The present invention also proposes a method for preparing highly flame-retardant and high-temperature-resistant automobile interior leather, comprising the following steps:

[0074] (1) fully mixing EPDM rubber, ethylene copolymer elastomer, co-crosslinking agent, flame retardant co-crosslinking agent, antioxidant, inorganic metal oxide, and other additives to obtain a mixture B;

[0075] (2) adding the mixture B obtained in step (1) into an extruder at an extrusion temperature of 70 to 130° C., extruding and casting the mixture onto a fabric base fabric through a T-shaped flat die, and winding the mixture to obtain a film material;

[0076] (3) irradiating the film obtained in step (2) with β rays or X rays, with an irradiation dose of 10 to 100 KGY;

[0077] (4) coating the film material irradiated in step (3), and obtaining a highly flame-retardant and high-temperature-resistant automotive interior leather after drying.

[0078] The present invention also proposes a method for preparing highly flame-retardant and high-temperature-resistant automobile interior leather, comprising the following steps:

[0079] (1) EPDM rubber, flame retardant co-crosslinking agent and peroxide are fully mixed, added into a granulator, the granulation temperature is 160-180° C., and granulated by the granulator to obtain mixture particles A;

[0080] (2) fully mixing the ethylene copolymer elastomer, the mixture particles A, the co-crosslinking agent, the antioxidant, the inorganic metal oxide and other additives to obtain a mixture B;

[0081] (3) adding the mixture B obtained in step (2) into an extruder at an extrusion temperature of 70 to 130° C., and extruding and casting the mixture onto a fabric base fabric through a T-shaped flat die to obtain a polyolefin substrate layer;

[0082] (4) coating the polyolefin substrate layer obtained in step (3) and drying it to obtain a surface coating;

[0083] (5) embossing the polyolefin substrate layer having the surface coating obtained in step (4);

[0084] (6) The film obtained in step (5) is irradiated with β rays or X rays, with an irradiation dose of 10 to 100 KGY to obtain highly flame-retardant and high-temperature resistant automotive interior leather.

[0085] In some embodiments, the automotive interior leather can be subjected to radiation cross-linking. This allows the polyolefin layer to have the desired degree of cross-linking, i.e., the polyolefin layer is a radiation-cross-linked polyolefin layer. Alpha rays, beta rays, gamma rays, X-rays, or neutron rays can be used for radiation cross-linking. It is easier to control the degree of cross-linking using electron beam radiation cross-linking, and the cross-linking process is more environmentally friendly. During radiation cross-linking, the film structure itself has no physical contact with the radiation generating device, and the shape of the film structure does not change before and after the reaction, but a cross-linking reaction has occurred inside it. As an example, beta rays (i.e., high-energy electron beams) can be used for radiation cross-linking. The irradiation dose can be selected as 5KGy~200KGy, 10KGy~100KGy, 20KGy~80KGy, or 50KGy~150KGy, etc.

[0086] In some embodiments, before the cross-linking step, a surface texture treatment step may be included. In the surface texture treatment step, the automotive interior leather may be subjected to surface texture treatment to form the desired texture. Thereafter, a cross-linking step is performed to obtain an automotive interior leather having surface texture. Thus, an automotive interior leather product with texture and three-dimensional style may be obtained. In some embodiments, the surface texture treatment step may include: vacuum forming, hot roller hot pressing or cold roller cold pressing to transfer the texture of the mold to the surface of the automotive interior leather. The aforementioned forming may be performed using a texture forming machine; the aforementioned hot pressing or cold pressing may be performed using an embossing machine. In the hot roller hot pressing method, the temperature of the hot roller may be equal to or slightly lower than the melting temperature of the polyolefin layer resin. Furthermore, the automotive interior leather with surface texture treatment can obtain good pattern retention after undergoing a subsequent cross-linking step.

[0087] Example

[0088] The following examples more specifically describe the disclosure of the present invention, which are intended for illustrative purposes only, as it will be apparent to those skilled in the art that various modifications and variations may be made within the scope of the disclosure. Unless otherwise stated, all parts, percentages, and ratios reported in the following examples are by weight, and the reagents and instruments used in the examples are commercially available.

[0089] The raw materials used in the following examples are selected from Table 1:

[0090] Table 1 Raw material grades and related properties used in the examples

[0091]

[0092] In addition to the above raw materials, the substrate layer also contains 0.5 parts of hindered phenol antioxidant.

[0093] The leather samples prepared in the examples were tested for performance as follows:

[0094] Flame retardancy: GB / T 8410 horizontal burning velocity test

[0095] Tensile strength and elongation at break: GB / T 1040.3-2006 "Determination of tensile properties of plastics Part 3: Test conditions for films and sheets"

[0096] Heat aging resistance: QBYDQ-A1901.402.2-2017 "Test methods for chemical properties of automotive interior and exterior trim"

[0097] Cross-linking degree: Detected by xylene extraction method in 5.5.3 of GB / T29848-2018 "Ethylene-vinyl acetate copolymer (EVA) adhesive film for photovoltaic module encapsulation";

[0098] Temperature resistance: No change in appearance after being placed at high temperature for 7 days

[0099] Example 1

[0100] A highly flame-retardant and high-temperature-resistant automobile interior leather comprises a polyolefin substrate layer and a polyurethane surface coating, wherein the polyolefin substrate layer comprises: 80 parts of XUS38680 POE resin, 20 parts of Sabic 756 EPDM rubber, 5 parts of zinc oxide, and 5 parts of tetraphenyl metaphenol diphosphate flame retardant co-crosslinking agent.

[0101] The method for preparing the automotive interior leather of this embodiment comprises the following steps:

[0102] (1) EPDM rubber, flame retardant co-crosslinking agent and peroxide are fully mixed and added into a granulator at a granulation temperature of 170° C., and granulated by the granulator to obtain mixture particles A;

[0103] (2) fully mixing the POE resin, the mixture particles A, the co-crosslinking agent, the antioxidant, the inorganic metal oxide and other additives to obtain a mixture B;

[0104] (3) adding the mixture B into an extruder at an extrusion temperature of 100° C., extruding and casting the mixture onto a fabric base fabric through a T-shaped flat die, and winding the mixture to obtain a film material;

[0105] (4) irradiating the film obtained in step (3) with β rays at a dose of 60 KGY;

[0106] (5) coating the film material irradiated in step (4), and obtaining a highly flame-retardant and high-temperature-resistant automotive interior leather after drying.

[0107] Example 2

[0108] The difference between Example 2 and Example 1 is that the flame retardant co-crosslinking agent is 5 parts of tetraphenyl bisphenol A diphosphate.

[0109] Example 3

[0110] The difference between Example 3 and Example 1 is that the flame retardant co-crosslinking agent is 5 parts of aromatic diphosphate.

[0111] Example 4

[0112] The difference between Example 4 and Example 1 is that the flame retardant co-crosslinking agent is 5 parts of bisphenol A bis(diphenyl) phosphate.

[0113] Example 5

[0114] This example is to prepare the structure and components of the automotive interior leather in Example 3, and the specific method is as follows:

[0115] (1) EPDM rubber, POE, a cross-linking agent, a flame retardant cross-linking agent, an antioxidant, an inorganic metal oxide, and other additives are fully mixed to obtain a mixture B;

[0116] (2) adding the mixture B obtained in step (1) into an extruder at an extrusion temperature of 130° C., extruding through a T-shaped flat die to form a film, and winding to obtain a film material;

[0117] (3) irradiating the film obtained in step (2) with β rays at a dose of 60 KGY;

[0118] (4) coating the film material irradiated in step (3), and obtaining a highly flame-retardant and high-temperature-resistant automotive interior leather after drying.

[0119] Example 6

[0120] This example is to prepare the structure and components of the automotive interior leather in Example 3, and the specific method is as follows:

[0121] (1) EPDM rubber, flame retardant co-crosslinking agent and peroxide are fully mixed and added into a granulator at a granulation temperature of 170° C., and granulated by the granulator to obtain mixture particles A;

[0122] (2) fully mixing the POE resin, the mixture particles A, the co-crosslinking agent, the antioxidant, the inorganic metal oxide and other additives to obtain a mixture B;

[0123] (3) adding the mixture B obtained in step (2) into an extruder at an extrusion temperature of 130° C., and extruding and casting the mixture onto a fabric base fabric through a T-shaped flat die to obtain a polyolefin substrate layer;

[0124] (4) coating the polyolefin substrate layer obtained in step (3) and drying it to obtain a surface coating;

[0125] (5) embossing the polyolefin substrate layer having the surface coating obtained in step (4);

[0126] (6) The film obtained in step (5) is subjected to β-ray irradiation with an irradiation dose of 60 KGY to obtain a highly flame-retardant and high-temperature resistant automotive interior leather.

[0127] Examples 7-10

[0128] The difference between Examples 7-10 and Example 3 is that different irradiation doses are used in the preparation process. Examples 7-10 use irradiation doses of 10 KGY, 30 KGY, 80 KGY, and 100 KGY, respectively.

[0129] Embodiment 11

[0130] The difference between Example 11 and Example 1 is that 5 parts of tetraphenyl metaphenol diphosphate flame retardant cross-linking agent are replaced by 1 part of triallyl isocyanurate cross-linking agent and 4 parts of trioctyl phosphate flame retardant cross-linking agent.

[0131] Example 12

[0132] The difference between Example 12 and Example 1 is that the polyolefin substrate layer includes: 80 parts of EVA resin EV270, 20 parts of EPDM rubber Sabic 756, 5 parts of zinc oxide, and 5 parts of aromatic diphosphate.

[0133] Comparative Example 1

[0134] The difference between Comparative Example 1 and Example 3 is that 5 parts of triallyl isocyanurate co-crosslinking agent replace 5 parts of aryl diphosphate flame retardant co-crosslinking agent.

[0135] Comparative Example 2

[0136] The difference between Comparative Example 2 and Example 3 is that the flame retardant is 5 parts of FRG-1530 nitrogen-phosphorus flame retardant, 1 part of triallyl isocyanurate cross-linking agent, and 4 parts of zinc oxide.

[0137] Comparative Example 3

[0138] The difference between Comparative Example 3 and Example 3 is that the amount of the aromatic diphosphate flame retardant co-crosslinking agent is 0.08 parts.

[0139] Comparative Example 4

[0140] The difference between Comparative Example 4 and Example 3 is that the amount of the aromatic diphosphate flame retardant co-crosslinking agent is 5.5 parts.

[0141] Comparative Example 5

[0142] The difference between Comparative Example 5 and Example 3 is that the irradiation dose is 5 KGY.

[0143] Comparative Example 6

[0144] The difference between Comparative Example 6 and Example 3 is that the irradiation dose is 110 KGY.

[0145] Comparative Examples 7-8

[0146] Comparative Examples 7-8 respectively selected commercially available PVC and TPU automotive interior leathers as comparative samples for performance comparison.

[0147] The performance test results are shown in Table 2

[0148]

Claims

1. A highly flame-retardant and high-temperature resistant automotive interior leather, comprising a polyolefin substrate layer and a surface coating, characterized in that: The polyolefin substrate layer comprises: A mixture of 10 to 90 parts by weight of an ethylene copolymer elastomer and 10 to 90 parts by weight of ethylene propylene diene monomer rubber, wherein the sum of the parts by weight of the ethylene copolymer elastomer and the ethylene propylene diene monomer rubber is 100 parts; 0.1-5 parts by weight of a cross-linking aid, wherein the cross-linking aid comprises a flame retardant cross-linking aid.

2. The highly flame-retardant and high-temperature-resistant automotive interior leather according to claim 1, characterized in that: The horizontal burning speed is less than 30mm / min.

3. The highly flame-retardant and high-temperature-resistant automotive interior leather according to claim 1, characterized in that: The flame retardant auxiliary cross-linking agent is selected from one or more of tetraphenyl bisphenol A diphosphate, bisphenol A bis(diphenyl) phosphate, aryl diphosphate, tetraphenyl m-phenol diphosphate, trimethyl diphenyl phosphate, alkane diaryl phosphonate, 2-ethylhexyl diphenyl phosphate, isodecyl diphenyl phosphate, tributyl phosphate, trioctyl phosphate, tributoxyethyl phosphate, dimethyl methyl phosphate, diethyl ethyl phosphate, and triaryl phosphonate.

4. The highly flame-retardant and high-temperature-resistant automotive interior leather according to claim 1, characterized in that: The ethylene copolymer elastomer is copolymerized by ethylene and another monomer, and the other monomer is selected from one of alpha olefins with a carbon chain length of C4-C8 or vinyl acetate.

5. The highly flame-retardant and high-temperature-resistant automobile interior leather according to claim 4, characterized in that: The other monomer is vinyl acetate, and the content of the vinyl acetate in the ethylene copolymer elastomer is greater than 10 wt % and less than 40 wt %.

6. The highly flame-retardant and high-temperature-resistant automobile interior leather according to claim 4, characterized in that: The other monomer is an alpha olefin with a carbon chain length of C4-C8.

7. The highly flame-retardant and high-temperature-resistant automobile interior leather according to claim 1, characterized in that: The auxiliary cross-linking agent also includes one or more of triallyl isocyanurate, triallyl cyanurate, glycidyl (meth)acrylate, methyl (meth)acrylate, trimethylolpropane trimethacrylate, propoxylated glycerol triacrylate, 2-carboxyethyl acrylate, isobornyl (meth)acrylate, 2-hydroxyethyl methacrylate phosphate and tripropylene glycol acrylate.

8. The highly flame-retardant and high-temperature-resistant automobile interior leather according to claim 1, characterized in that: The polyolefin substrate layer has a cross-linking degree of at least 40%, and the cross-linking method is electron beam irradiation cross-linking.

9. The highly flame-retardant and high-temperature-resistant automobile interior leather according to claim 1, characterized in that: The polyolefin substrate layer further contains a phosphonate or hindered phenol antioxidant.

10. The highly flame-retardant and high-temperature-resistant automobile interior leather according to claim 1, characterized in that: The polyolefin substrate layer further contains an inorganic metal oxide.

11. A method for preparing the automotive interior leather according to claims 1-10, characterized in that: The following steps are involved: (1) the EPDM rubber, the flame retardant co-crosslinking agent and the peroxide are fully mixed and added into a granulator at a granulation temperature of 160 to 180° C., and granulated by the granulator to obtain mixture particles A; (2) fully mixing the ethylene copolymer elastomer, the mixture particles A, the co-crosslinking agent, the antioxidant, the inorganic metal oxide and other additives to obtain a mixture B; (3) adding the mixture B into an extruder at an extrusion temperature of 50 to 130° C., extruding through a T-shaped flat die to form a film, and winding to obtain a film material; (4) irradiating the film obtained in step (3) with β rays or X rays, with an irradiation dose of 10 to 100 KGY; (5) coating the film material irradiated in step (4), and obtaining a highly flame-retardant and high-temperature-resistant automotive interior leather after drying.

12. A method for preparing the automotive interior leather according to claims 1-10, characterized in that: The following steps are involved: (1) fully mixing the EPDM rubber, the ethylene copolymer elastomer, the co-crosslinking agent, the flame retardant co-crosslinking agent, the antioxidant, the inorganic metal oxide, and other additives to obtain a mixture B; (2) adding the mixture B obtained in step (1) into an extruder at an extrusion temperature of 70 to 130° C., extruding and casting the mixture onto a fabric base fabric through a T-shaped flat die, and winding the mixture to obtain a film material; (3) irradiating the film obtained in step (2) with β rays or X rays, with an irradiation dose of 10 to 100 KGY; (4) coating the film material irradiated in step (3), and obtaining a highly flame-retardant and high-temperature-resistant automotive interior leather after drying.

13. A method for preparing the automotive interior leather according to claims 1-10, characterized in that: The following steps are involved: (1) the EPDM rubber, the flame retardant co-crosslinking agent and the peroxide are fully mixed, added into a granulator, the granulation temperature is 160-180° C., and granulated by the granulator to obtain mixture particles A; (2) fully mixing the ethylene copolymer elastomer, the mixture particles A, the co-crosslinking agent, the antioxidant, the inorganic metal oxide and other additives to obtain a mixture B; (3) adding the mixture B obtained in step (2) into an extruder at an extrusion temperature of 70 to 130° C., and extruding and casting the mixture onto a fabric base fabric through a T-shaped flat die to obtain a polyolefin substrate layer; (4) coating the polyolefin substrate layer obtained in step (3) and drying it to obtain a surface coating; (5) embossing the polyolefin substrate layer having the surface coating obtained in step (4); (6) The film obtained in step (5) is irradiated with β rays or X rays, with an irradiation dose of 10 to 100 KGY to obtain highly flame-retardant and high-temperature resistant automotive interior leather.

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