Flame-retardant automotive carpet and preparation method thereof

Abstract

The invention belongs to the technical field of automobile carpets, and particularly relates to a flame-retardant automobile carpet and a preparation method thereof.The flame-retardant automobile carpet comprises a carpet body and positioning structures symmetrically arranged at the four corners of the carpet body, and the carpet body comprises a surface wear-resisting layer, a flame-retardant composite layer, an elastic layer and a bottom anti-skid layer which are sequentially arranged and fixedly connected; the surface wear-resistant layer is formed by weaving PET fibers and low-melting-point fibers, the flame-retardant composite layer comprises an upper fireproof layer, a flame-retardant core layer and a lower fireproof layer symmetrical to the upper fireproof layer, the upper fireproof layer and the lower fireproof layer are PVC coatings mixed with flame-retardant particles, and the elastic layer is formed by compounding a porous PET fiber structure and a solvent-free polyurethane foaming material. The bottom anti-skid layer comprises a back adhesive sticker, and sub-mother stickers in the back adhesive sticker are arranged at the bottom of the elastic layer and a pedal area of an automobile respectively.

Description

Technical Field

[0001] The present invention relates to the technical field of automotive carpets, and particularly relates to a flame-retardant automotive carpet and a preparation method thereof. Background Art

[0002] With the development of the automotive industry, the types and quantities of automotive interior parts are increasing day by day. Among them, the carpet is an important component of automotive interior parts. The carpet can not only beautify the interior environment of the vehicle, but also play roles such as sound insulation, shock absorption, and dust collection. However, traditional automotive carpets are usually made of multiple layers of fiber materials, and these fiber materials are prone to burning when encountering high temperature or open fire, thus triggering a fire and causing losses of life and property. Therefore, how to improve the flame-retardant performance of automotive carpets has become an urgent problem to be solved in the automotive industry. Summary of the Invention

[0003] Aiming at the problems existing above, the present invention specifically designs a flame-retardant automotive carpet and a preparation method thereof to improve the flame-retardant performance of the automotive carpet.

[0004] To achieve the above object, the present invention provides a flame-retardant automotive carpet, which includes a carpet body and positioning structures symmetrically arranged at four corners of the carpet body. The carpet body includes a surface wear-resistant layer, a flame-retardant composite layer, an elastic layer, and a bottom anti-slip layer that are sequentially arranged and fixedly connected. The surface wear-resistant layer is woven by PET fibers and low-melting-point fibers. The flame-retardant composite layer includes an upper fireproof layer, a flame-retardant core layer, and a lower fireproof layer symmetrically arranged with the upper fireproof layer. Both the upper fireproof layer and the lower fireproof layer are PVC coatings mixed with flame-retardant particles. The elastic layer is composed of a porous PET fiber structure and a solvent-free polyurethane foam material. The bottom anti-slip layer includes a back adhesive sticker, and the male and female stickers in the back adhesive sticker are respectively arranged at the bottom of the elastic layer and the footrest area of the vehicle.

[0005] Preferably, the flame-retardant core layer is made by mixing the following components by weight: 50 - 70 parts of PP fibers, 5 - 15 parts of a flame retardant, 1 - 3 parts of an antioxidant, and 0.5 - 1.5 parts of an ultraviolet absorber.

[0006] Preferably, the fineness of the PP fibers is 1.5 - 3D, and the length is 30 - 50 mm.

[0007] Preferably, the flame retardant is antimony trioxide, the antioxidant is triphenyl phosphite, and the ultraviolet absorber is 2,4-dihydroxybenzophenone.

[0008] Further, the positioning structure includes a bottom plate, a first pin shaft, a pressing plate and a first limiting post. A limiting strip is fixedly connected to the pedal area of the vehicle. The bottom plate is fixedly connected with a plug board matching the limiting strip. The pressing plate is rotationally connected to the bottom plate through the first pin shaft, and positioning grooves are formed in both the bottom plate and the pressing plate. The first limiting post is fixedly arranged in the limiting groove of the bottom plate.

[0009] Further, the positioning structure further includes a volute spring. Two free ends of the volute spring are respectively fixedly connected to the bottom plate and the pressing plate.

[0010] Further, the pressing plate is provided with a semi-open arc-shaped guide rail. The pressing plate is rotationally connected with a positioning plate adapted to the first limiting post, and the guide rail is provided with a slot matching the positioning plate.

[0011] Further, a magnetic attraction plate is additionally installed on the pressing plate, and the magnetic attraction plate is magnetically connected to the positioning plate.

[0012] The present invention further includes a preparation method of a flame-retardant automotive carpet, comprising the following steps: 1). Loosen PET fibers and low-melting-point fibrid fibers, card and mix the loosened fibers and then weave them to form a semi-finished product of a surface wear-resistant layer. The proportion of the low-melting-point fibers is 4% - 10%. Bidirectionally needle-punch and bond the semi-finished product of the surface wear-resistant layer through a high-speed needle-punching machine, and form a finished product of the surface wear-resistant layer through hot pressing. 2). Mix PP fibers, a flame retardant, an antioxidant and an ultraviolet absorber evenly to obtain a mixture. Melt-spin the mixture to obtain a fiber material of a flame-retardant core layer, and weave the fiber material to obtain a finished product of the flame-retardant core layer. The temperature of the melt spinning is 200 - 250 °C, and the weaving density of the fiber material is 50 - 100 pieces / cm². 3). Adopt a spraying process to sequentially prepare a top fireproof layer and a bottom fireproof layer on both sides of the flame-retardant core layer. 4). Adopt a PET fiber fabric, form a porous PET fiber structure through melt spinning. After fully stirring the solvent-free polyurethane foaming material evenly, coat and fill it in the porous PET fiber structure, and cure it until it is dried to form an elastic layer. 5). Stack layers in the order of "surface wear-resistant layer - flame-retardant composite layer - elastic layer", and compound them through a roller hot press, and cut and edge the carpet after cooling. 6). Install an adhesive sticker at the bottom of the elastic layer.

[0013] In summary, the present invention has the following advantages and beneficial technical effects: 1. For the carpet body of the present invention, since at least one layer has flame-retardant performance, the automotive carpet will not burn rapidly in case of a fire, thus effectively reducing the risk of fire occurrence.

[0014] 2. The material of the surface wear-resistant layer includes modified PET fiber, among which the low-melting-point fiber has the advantages of low carbon and environmental protection, easy thermal bonding, and good thermal stability. It not only has good flame retardant properties and effectively protects the lives of passengers, but also has good durability and prolongs the service life.

[0015] 3. The present invention can improve not only the flame retardant performance of the carpet, but also its antioxidant performance and anti-ultraviolet performance by adding flame retardants, antioxidants and ultraviolet absorbers to the flame retardant composite layer, thereby extending its service life.

[0016] 4. The elastic layer preparation method of the present invention is simple, easy to operate, suitable for large-scale production, and has good comfort and can provide a good riding experience.

[0017] 5. The bottom anti-skid layer and the positioning structure of the present invention can prevent the car carpet from sliding during the driving of the vehicle, thereby improving the driving comfort and safety.

[0018] 6. In the present invention, the bottom plate, the pressure plate and the first limiting column work together to limit the displacement of the carpet body; the spiral spring stores elastic potential energy during the rotation of the pressure plate, which is used for the self-rotation reset of the pressure plate; the arc guide rail is used to limit the first limiting column, thereby ensuring the accuracy of the rotation path of the pressure plate.

[0019] 7. In the present invention, the positioning plate cooperates with the arc guide rail to realize all-round restriction of the first limit column. The magnetic attraction plate uses the magnetic principle to attract the positioning plate to rotate and reset, and restrict the unidirectional rotation of the positioning plate. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] The above and / or additional aspects and advantages of the present invention will become apparent and easily understood from the description of the embodiments in conjunction with the following drawings, in which: Figure 1 It is a schematic diagram of the structure of the present invention; Figure 2 It is a schematic diagram of the main view of the carpet body of the present invention; Figure 3 It is a front view schematic diagram of the positioning structure in the present invention; Figure 4 It is a three-dimensional schematic diagram of the positioning structure in the present invention; Figure 5 It is a top view schematic diagram of a part of the positioning structure of the present invention; Figure 6 It is the use state of the first limit column in the present invention Figure 1 ; Figure 7 It is the use state of the first limit column in the present invention Figure 2 .

[0021] The reference numerals in the drawings are as follows: 1. Carpet body; 11. Surface wear-resistant layer; 12. Upper fireproof layer; 13. Flame-retardant core layer; 14. Lower fireproof layer; 15. Elastic layer; 16. Bottom anti-slip layer; 2. Positioning structure; 21. Bottom plate; 22. First pin shaft; 23. Pressure plate; 24. First limit post; 25. Insertion plate; 26. Volute spring; 27. Guide rail; 28. Positioning plate; 29. Magnetic attraction plate. Detailed implementation manners

[0022] To make the objectives, technical solutions and advantages of the implementation of the present invention clearer, the technical solutions in the embodiments of the present invention will be described in more detail below with reference to the drawings in the embodiments of the present invention. In the drawings, the same or similar reference numerals throughout denote the same or similar elements or elements having the same or similar functions; the described embodiments are some but not all of the embodiments of the present invention; the embodiments described below with reference to the drawings and directional terms are all exemplary and are intended to explain the present invention and should not be construed as a limitation to the present invention; based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative efforts shall fall within the scope of protection of the present invention. The embodiments of the present invention will be described in detail below with reference to the drawings: The following will further elaborate on the present invention with reference to the attached Figures 1-7 This invention will be further described in detail as follows: Embodiment 1 As Figures 1-2 shown, this embodiment discloses a flame-retardant automotive carpet, including a carpet body 1 and positioning structures 2 symmetrically arranged at the four corners of the carpet body 1. The carpet body 1 includes a surface wear-resistant layer 11, a flame-retardant composite layer, an elastic layer 15, and a bottom anti-slip layer 16 that are sequentially arranged and fixedly connected. The surface wear-resistant layer 11 is woven from PET fibers and low-melting-point fibers. In this embodiment, the low-melting-point fiber is a PE / PP double-layer composite fiber. The flame-retardant composite layer includes an upper fireproof layer 12, a flame-retardant core layer 13, and a lower fireproof layer 14 that are sequentially arranged. Both the upper fireproof layer 12 and the lower fireproof layer 14 are PVC coatings mixed with flame-retardant particles. The elastic layer 15 is composed of a composite of a porous PET fiber structure and a solvent-free polyurethane foam material. The bottom anti-slip layer 16 includes a back adhesive sticker, and the mother and son stickers of the back adhesive sticker are respectively adhered to the bottom of the elastic layer 15 and the footrest area of the vehicle.

[0023] As Figures 1-2 shown, in this embodiment, the flame-retardant core layer 13 is made by mixing the following components by weight: 65 parts of PP fibers, 7 parts of antimony trioxide, 2.5 parts of triphenyl phosphite, and 1.2 parts of 2,4-dihydroxybenzophenone; among them, the fineness of the PP fibers is 2D and the length is 40 mm.

[0024] As shown Figure 3 in FIG. Figure 3 , the positioning structure 2 includes a bottom plate 21, a first pin shaft 22, a pressing plate 23 and a first limit post 24. An inverted U-shaped limit strip is welded to the pedal area of the vehicle. An L-shaped insertion plate 25 matching the limit strip is fixedly connected to the bottom plate 21. The pressing plate 23 is rotatably connected to the bottom plate 21 through the first pin shaft 22. The longitudinal section of the first pin shaft 22 is in an I shape. Opposite positioning grooves are formed in the bottom plate 21 and the pressing plate 23. The first limit post 24 is fixedly arranged in the positioning groove of the bottom plate 21.

[0025] As shown Figures 4-5 in FIG. Figures 4-5 , the positioning structure 2 further includes a scroll spring 26. Two free ends of the scroll spring 26 are respectively fixedly connected to the bottom plate 21 and the pressing plate 23 through pin shafts.

[0026] As shown Figures 5-7 in FIG. Figures 5-7 , the pressing plate 23 is provided with a semi-open arc-shaped guide rail 27. In this embodiment, the axis of the first pin shaft 22 and the axis of the first limit post 24 are symmetric about the center point of the bottom plate 21. The center of the arc in the guide rail 27 coincides with the axis of the first pin shaft 22. The pressing plate 23 is rotatably connected with an L-shaped positioning plate 28 adapted to the first limit post 24. The guide rail 27 is provided with a slot for the positioning plate 28 to rotate; A magnetic attraction plate 29 is further installed on the pressing plate 23. One side of the positioning plate 28 is magnetically connected to the magnetic attraction plate 29 through a magnet.

[0027] The working principle of the positioning structure 2 in a flame-retardant automotive carpet of the present invention is as follows: Manually operate, rotate the pressing plate 23 clockwise by 90°, pass the first limit post 24 through the through hole opened in the carpet body 1, and then the worker releases the hand. The elastic potential energy stored in the scroll spring 26 is released, driving the pressing plate 23 to rotate back. The bottom plate 21 and the pressing plate 23 cooperate to clamp the corner of the carpet body 1; During the rotation-back process of the pressing plate 23, the first limit post 24 slides in the guide rail 27 and pushes the positioning plate 28 to rotate back. Finally, under the magnetic force of the magnetic attraction plate 29, the positioning plate 28 completes the rotation and resets; Sequentially install the positioning structures 2 at the four corners of the carpet body 1, and insert the insertion plate 25 into the limit strip in the pedal area of the vehicle to realize the quick disassembly, assembly and positioning of the carpet body 1.

[0028] Embodiment 2 The preparation method of a flame-retardant automotive carpet of the present invention is as follows: Step 1: Prepare the surface wear-resistant layer 11. Open and loosen PET fibers and low-melting-point fiberized fibers, straighten and mix the wires after loosening to form a semi-finished product. The proportion of low-melting-point fibers is 5%. Use a high-speed needle punching machine to carry out double-sided needle punching and bonding reinforcement on the semi-finished product, and form the finished product of the surface wear-resistant layer 11 through hot pressing. Step 2: Prepare the flame-retardant core layer 13. Mix PP fibers, a flame retardant, an antioxidant, and an ultraviolet absorber evenly to obtain a mixture. Melt-spin the mixture at a spinning temperature of 240°C to obtain the fiber material of the flame-retardant core layer 13. Weave the fiber material with a weaving density of 60 threads / cm² to obtain the finished product of the flame-retardant core layer 13; Step 3: Assemble the flame-retardant composite layer. Using a spraying process, sequentially prepare the upper fireproof layer 12 and the lower fireproof layer 14 on both sides of the flame-retardant core layer 13, and then dry it; Step 4: Prepare the elastic layer 15. Use a PET fiber fabric to form a porous PET fiber structure through melt spinning. Composite and fill the porous PET fiber structure with a solvent-free polyurethane foam material, and cure it until it is dried. In this embodiment, the composite of the solvent-free polyurethane foam material and the porous PET fiber structure is a prior art. For the specific preparation method, refer to CN119041102A, and it will not be elaborated here; Step 5: Stack layers in the order of "surface wear-resistant layer 11 - flame-retardant composite layer - elastic layer 15", and composite them through a double-roll hot press at a temperature of 160~180°C and a pressure of 10~15 MPa. After cooling, cut and edge-wrap; Step 6: Stick an adhesive sticker on the bottom of the elastic layer 15.

[0029] Finally, it should be pointed out that the above embodiments are only used to illustrate the technical solutions of the present invention, and are not intended to limit them. Although the present invention has been described in detail with reference to the foregoing embodiments, those of ordinary skill in the art should understand that they can still modify the technical solutions described in the foregoing embodiments, or perform equivalent replacements for some of the technical features; and these modifications or replacements do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A flame retardant automotive carpet, characterized in that: The invention comprises a carpet body and positioning structures symmetrically arranged at the four corners of the carpet body, wherein the carpet body comprises a surface wear-resistant layer, a flame-retardant composite layer, an elastic layer and a bottom anti-slip layer which are arranged in sequence and fixedly connected, wherein the surface wear-resistant layer is woven from PET fiber and low-melting-point fiber, the flame-retardant composite layer comprises an upper fireproof layer, a flame-retardant core layer, and a lower fireproof layer symmetrically arranged with the upper fireproof layer, wherein both the upper fireproof layer and the lower fireproof layer are PVC coatings mixed with flame-retardant particles, the elastic layer is composited from a porous PET fiber structure and a solvent-free polyurethane foam material, and the bottom anti-slip layer comprises an adhesive sticker, wherein the mother-and-child stickers in the adhesive sticker are respectively arranged at the bottom of the elastic layer and in the pedal area of ​​the car.

2. The flame-retardant automotive carpet according to claim 1, characterized in that: The flame retardant core layer is made by mixing the following components by weight: 50-70 parts of PP fiber, 5-15 parts of flame retardant, 1-3 parts of antioxidant, and 0.5-1.5 parts of ultraviolet absorber.

3. The flame-retardant automotive carpet according to claim 2, characterized in that: The PP fiber has a fineness of 1.5-3D and a length of 30-50 mm.

4. The flame-retardant automotive carpet according to claim 2, characterized in that: The flame retardant is antimony trioxide, the antioxidant is triphenyl phosphite, and the ultraviolet absorber is 2,4-dihydroxybenzophenone.

5. The flame-retardant automotive carpet according to claim 1, characterized in that: The positioning structure includes a base plate, a first pin shaft, a pressure plate and a first limiting column. The footrest area of ​​the car is fixedly connected to the limiting strip, the base plate is fixedly connected to a plug plate matching the limiting strip, the pressure plate is rotatably connected to the base plate via the first pin shaft, and both the base plate and the pressure plate are provided with positioning grooves, and the first limiting column is fixedly arranged in the positioning groove of the base plate.

6. The flame-retardant automotive carpet according to claim 5, characterized in that: The positioning structure also includes a spiral spring, and two free ends of the spiral spring are respectively fixedly connected to the bottom plate and the pressure plate.

7. The flame-retardant automotive carpet according to claim 5, characterized in that: The pressing plate is provided with a semi-open arc-shaped guide rail, the pressing plate is rotatably connected with a positioning plate adapted to the first limiting column, and the guide rail is provided with a slot matched with the positioning plate.

8. The flame-retardant automotive carpet according to claim 7, characterized in that: The pressing plate is further provided with a magnetic attraction plate, and the magnetic attraction plate is magnetically connected to the positioning plate.

9. A method for preparing a flame retardant automotive carpet, characterized in that: The steps of preparing the flame-retardant automotive carpet according to claim 3 are: Step 1: Open the PET fiber and the low-melting-point fiber, sort the fibers and mix them to form a semi-finished product with a surface wear-resistant layer. The low-melting-point fiber accounts for 4% to 10%. The semi-finished product with the surface wear-resistant layer is reinforced by bidirectional needle punching through a high-speed needle punching machine, and the surface wear-resistant layer is formed into a finished product through hot pressing; Step 2: Evenly mix the PP fiber, the flame retardant, the antioxidant and the ultraviolet absorber to obtain a mixture, melt-spin the mixture to obtain a fiber material of the flame-retardant core layer, and weave the fiber material to obtain a finished product of the flame-retardant core layer; Step 3: Using a spraying process, an upper fireproof layer and a lower fireproof layer are sequentially prepared on both sides of the flame retardant core layer; Step 4: using PET fiber fabric, forming a porous PET fiber structure by melt spinning, compounding and filling the porous PET fiber structure with a solvent-free polyurethane foam material, aging and drying, and forming an elastic layer; Step 5: stack the layers in the order of "surface wear-resistant layer - flame-retardant composite layer - elastic layer", compound them through a roller hot press, and cut and wrap the edges after cooling; Step 6: Install the adhesive sticker at the bottom of the elastic layer.

10. The method for preparing a flame retardant automotive carpet according to claim 9, characterized in that: In the step 2, the temperature of melt spinning is 200-250° C., and the weaving density of the fiber material is 50-100 strands / cm².

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