Flame-retardant automotive carpet and method of making same

Abstract

The present application belongs to the technical field of automobile carpet, and particularly relates to a kind of flame-retardant automobile carpet and its preparation method, including carpet body and positioning structure symmetrically arranged at four corners of the carpet body, the carpet body includes sequentially arranged and fixedly connected surface wear-resistant layer, flame-retardant composite layer, elastic layer and bottom anti-skid layer, the surface wear-resistant layer is woven from PET fiber and low-melting fiber, the flame-retardant composite layer includes upper fireproof layer, flame-retardant core layer, and lower fireproof layer symmetrically arranged with the upper fireproof layer, the upper fireproof layer and the lower fireproof layer are both PVC coating mixed with flame-retardant particles, the elastic layer is composed of porous PET fiber structure and solvent-free polyurethane foaming material, the bottom anti-skid layer includes back adhesive paste, and the sub-mother paste in the back adhesive paste is arranged at the bottom of the elastic layer and the foot area of the automobile respectively, the beneficial effects of the present application are: improving the flame-retardant performance of the automobile carpet.

Description

Technical Field

[0001] This invention relates to the field of automotive carpet technology, specifically to a flame-retardant automotive carpet and its preparation method. Background Technology

[0002] With the development of the automotive industry, the types and quantities of automotive interior parts are increasing daily, among which carpets are an important component. Carpets not only beautify the car interior environment but also provide sound insulation, shock absorption, and dust absorption. However, traditional automotive carpets are usually made of multiple layers of fiber materials, which are easily flammable when exposed to high temperatures or open flames, potentially causing fires and resulting in loss of life and property. Therefore, improving the flame-retardant properties of automotive carpets has become an urgent problem to be solved in the automotive industry. Summary of the Invention

[0003] The present invention addresses the problems mentioned above by designing a flame-retardant automotive carpet and its preparation method, thereby improving the flame-retardant performance of automotive carpets.

[0004] To achieve the above objectives, the present invention provides a flame-retardant automotive carpet, comprising a carpet body and positioning structures symmetrically arranged at the 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 arranged sequentially and fixedly connected. The surface wear-resistant layer is woven from 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 and lower fireproof layers 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 an adhesive backing, in which the mother and daughter adhesive strips are respectively disposed at the bottom of the elastic layer and the footwell area of ​​the car.

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

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

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

[0008] Furthermore, the positioning structure includes a base plate, a first pin, a pressure plate, and a first limiting post. The foot pedal area of ​​the car is fixedly connected to a limiting strip. The base plate is fixedly connected to an insert plate that matches the limiting strip. The pressure plate is rotatably connected to the base plate through the first pin. Both the base plate and the pressure plate are provided with positioning grooves. The first limiting post is fixedly installed in the limiting groove of the base plate.

[0009] Furthermore, the positioning structure also includes a spiral spring, the two free ends of which are fixedly connected to the base plate and the pressure plate, respectively.

[0010] Furthermore, the pressure plate is provided with a semi-open arc-shaped guide rail, and the pressure plate is rotatably connected to a positioning plate that is adapted to the first limiting post. The guide rail is provided with a slot that matches the positioning plate.

[0011] Furthermore, the pressure plate is also equipped with a magnetic suction plate, which is magnetically connected to the positioning plate.

[0012] This invention also includes a method for preparing a flame-retardant automotive carpet, comprising the following steps:

[0013] 1) PET fiber and low melting point chemical fiber are opened, loosened and then mixed and woven to form a semi-finished product with a surface wear-resistant layer. The low melting point fiber accounts for 4%~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 made into a finished product by hot pressing.

[0014] 2) Mix PP fiber, flame retardant, antioxidant and ultraviolet absorber evenly to obtain a mixture. Melt spin the mixture to obtain the fiber material of the flame retardant core layer. Weave the fiber material to obtain the finished flame retardant core layer.

[0015] The melt spinning temperature is 200~250℃, and the fiber material weaving density is 50~100 threads / cm².

[0016] 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;

[0017] 4) Using PET fiber fabric, a porous PET fiber structure is formed by melt spinning. Solvent-free polyurethane foam material is thoroughly stirred and then coated and filled into the porous PET fiber structure. It is then cured until dried to form an elastic layer.

[0018] 5) Lay the layers in the order of “surface wear-resistant layer - flame-retardant composite layer - elastic layer”, combine them by roller hot press, and cut and wrap the edges after cooling;

[0019] 6) Install adhesive backing on the bottom of the elastic layer.

[0020] In summary, the present invention has the following advantages and beneficial technical effects:

[0021] 1. The carpet body of the present invention, since at least one layer has flame-retardant properties, will not burn rapidly in the event of a fire, thereby effectively reducing the risk of fire.

[0022] 2. The surface wear-resistant layer is made of modified PET fiber, among which the low-melting-point fiber has the advantages of being low-carbon and environmentally friendly, easy to heat bond, and good thermal stability. It not only has good flame retardant properties to effectively protect the lives of passengers, but also has good durability and extends service life.

[0023] 3. By adding flame retardants, antioxidants, and ultraviolet absorbers to the flame-retardant composite layer, this invention can not only improve the flame retardant properties of carpets, but also improve their antioxidant and ultraviolet resistance properties, thereby extending their service life.

[0024] 4. The elastic layer preparation method of the present invention is simple, easy to operate, suitable for large-scale production, and has good comfort, providing a good riding experience.

[0025] 5. The bottom anti-slip layer and positioning structure in this invention can prevent the car carpet from sliding during vehicle operation, thereby improving driving comfort and safety.

[0026] 6. In this invention, the base plate, pressure plate, and first limiting post 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 and reset of the pressure plate; the arc-shaped guide rail is used to limit the first limiting post, thereby ensuring the accuracy of the rotation path of the pressure plate.

[0027] 7. In this invention, the positioning plate, in conjunction with the arc-shaped guide rail, achieves all-round restriction of the first limiting post. The magnetic plate uses the principle of magnetism to attract the positioning plate to rotate and reset, and restricts the unidirectional rotation of the positioning plate. Attached Figure Description

[0028] The above and / or additional aspects and advantages of the present invention will become apparent and readily understood from the description of the embodiments taken in conjunction with the following drawings, in which:

[0029] Figure 1 This is a schematic diagram of the structure of the present invention;

[0030] Figure 2 This is a front view schematic diagram of the carpet body in this invention;

[0031] Figure 3 This is a front view schematic diagram of the positioning structure in this invention;

[0032] Figure 4 This is a three-dimensional schematic diagram of the positioning structure in this invention;

[0033] Figure 5 This is a top view of a portion of the positioning structure of the present invention;

[0034] Figure 6 This is the usage state of the first limiting post in this invention. Figure 1 ;

[0035] Figure 7 This is the usage state of the first limiting post in this invention. Figure 2 .

[0036] The reference numerals in the attached figures are:

[0037] 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;

[0038] 2. Positioning structure; 21. Base plate; 22. First pin; 23. Pressure plate; 24. First limiting post; 25. Insert plate; 26. Scroll spring; 27. Guide rail; 28. Positioning plate; 29. ​​Magnetic suction plate. Detailed Implementation

[0039] To make the objectives, technical solutions, and advantages of this invention clearer, the technical solutions of the embodiments of this invention will be described in more detail below with reference to the accompanying drawings. In the drawings, the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout; the described embodiments are some embodiments of this invention, but not all embodiments; the embodiments and directional terms described below with reference to the accompanying drawings are exemplary and intended to explain this invention, and should not be construed as limiting this invention; all other embodiments obtained by those skilled in the art based on the embodiments of this invention without creative effort are within the scope of protection of this invention. The embodiments of this invention will be described in detail below with reference to the accompanying drawings:

[0040] The following is in conjunction with the appendix Figures 1-7 The present invention will be further described in detail below:

[0041] Example 1

[0042] like Figures 1-2As shown, this embodiment discloses a flame-retardant car 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 arranged sequentially 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 fibers are PE / PP double-layer composite fibers. The flame-retardant composite layer includes an upper fireproof layer 12, a flame-retardant core layer 13, and a lower fireproof layer 14 arranged sequentially. The upper fireproof layer 12 and the lower fireproof layer 14 are both PVC coatings mixed with flame-retardant particles. The elastic layer 15 is composed of a porous PET fiber structure and a solvent-free polyurethane foam material. The bottom anti-slip layer 16 includes an adhesive backing, with the adhesive backing's mother and daughter pieces respectively attached to the bottom of the elastic layer 15 and the footwell area of ​​the car.

[0043] like Figures 1-2 As shown, in this embodiment, the flame-retardant core layer 13 is made of the following components by weight: 65 parts PP fiber, 7 parts antimony trioxide, 2.5 parts triphenyl phosphite, and 1.2 parts 2,4-dihydroxybenzophenone; wherein the PP fiber has a fineness of 2D and a length of 40mm.

[0044] like Figure 3 As shown, the positioning structure 2 includes a base plate 21, a first pin 22, a pressure plate 23, and a first limiting post 24. The foot pedal area of ​​the car is welded with an inverted U-shaped limiting strip. The base plate 21 is fixedly connected with an L-shaped insert 25 that matches the limiting strip. The pressure plate 23 is rotatably connected to the base plate 21 through the first pin 22. The longitudinal section of the first pin 22 is I-shaped. The base plate 21 and the pressure plate 23 are provided with corresponding positioning grooves. The first limiting post 24 is fixedly set in the positioning groove of the base plate 21.

[0045] like Figures 4-5 As shown, the positioning structure 2 also includes a spiral spring 26, the two free ends of which are fixedly connected to the base plate 21 and the pressure plate 23 by pins.

[0046] like Figures 5-7 As shown, the pressure plate 23 is provided with a semi-open arc-shaped guide rail 27. In this embodiment, the axis of the first pin 22 and the axis of the first limiting post 24 are symmetrical about the center point of the base plate 21. The center of the arc in the guide rail 27 coincides with the axis of the first pin 22. The pressure plate 23 is rotatably connected to an L-shaped positioning plate 28 that is adapted to the first limiting post 24. The guide rail 27 is provided with a slot for the positioning plate 28 to rotate. The pressure plate 23 is also equipped with a magnetic suction plate 29. One side of the positioning plate 28 is magnetically connected to the magnetic suction plate 29 through a magnet.

[0047] The working principle of the positioning structure 2 in the flame-retardant automotive carpet of the present invention is as follows:

[0048] Manually, the pressure plate 23 is rotated 90° clockwise, and the first limiting post 24 is passed through the through hole in the carpet body 1. The worker releases the pressure plate 23, which rotates the pressure plate 23. The base plate 21 and the pressure plate 23 cooperate to clamp the corner of the carpet body 1. During the rotation of the pressure plate 23, the first limiting post 24 slides within the guide rail 27 and pushes the positioning plate 28 to rotate. Finally, under the magnetic force of the magnetic suction plate 29, the positioning plate 28 completes its rotation and reset. The positioning structures 2 at the four corners of the carpet body 1 are installed in sequence, and the insert plate 25 is inserted into the limiting strip in the car foot pedal area to achieve quick disassembly, assembly, and positioning of the carpet body 1.

[0049] Example 2

[0050] The present invention provides a method for preparing a flame-retardant automotive carpet as follows:

[0051] Step 1: Prepare the surface wear-resistant layer 11. Loosen PET fibers and low-melting-point chemical fibers, sort the loose fibers and mix and weave them to form a semi-finished product. The low-melting-point fiber accounts for 5%. The semi-finished product is needled and reinforced in both the upper and lower directions by a high-speed needle punching machine, and then hot-pressed to form the finished product of the surface wear-resistant layer 11.

[0052] Step 2: Prepare the flame-retardant core layer 13. Mix PP fiber, flame retardant, antioxidant and ultraviolet absorber evenly to obtain a mixture. Melt spin the mixture at a spinning temperature of 240℃ to obtain the fiber material of the flame-retardant core layer 13. Weave the fiber material at a weaving density of 60 threads / cm² to obtain the finished product of the flame-retardant core layer 13.

[0053] Step 3: Assemble the flame-retardant composite layer. Using a spraying process, prepare the upper fireproof layer 12 and the lower fireproof layer 14 sequentially on both sides of the flame-retardant core layer 13, and then dry them.

[0054] Step 4: Prepare elastic layer 15 using PET fiber fabric. Form a porous PET fiber structure through melt spinning. Fill the porous PET fiber structure with solvent-free polyurethane foam material and cure until dry. In this embodiment, the combination of solvent-free polyurethane foam material and porous PET fiber structure is a prior art. For the specific preparation method, refer to CN119041102A, which will not be elaborated here.

[0055] Step 5: Lay the layers in the order of “surface wear-resistant layer 11 - flame-retardant composite layer - elastic layer 15”, and then laminate them using a double-roller hot press at a temperature of 160~180℃ and a pressure of 10~15MPa. After cooling, cut and wrap the edges.

[0056] Step 6: Apply adhesive backing to the bottom of elastic layer 15.

[0057] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features; and these modifications or substitutions 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 carpet includes a carpet body and positioning structures symmetrically arranged at the 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 arranged sequentially and fixedly connected. The surface wear-resistant layer is woven from 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 and lower fireproof layers 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 an adhesive backing, in which the mother and daughter stickers are respectively arranged at the bottom of the elastic layer and the footwell of the car. The positioning structure includes a base plate, a first pin, a pressure plate, and a first limiting post. The foot pedal area of ​​the car is fixedly connected to a limiting strip. The base plate is fixedly connected to an insert plate that matches the limiting strip. The pressure plate is rotatably connected to the base plate through the first pin. Both the base plate and the pressure plate are provided with positioning grooves. The first limiting post is fixedly installed in the positioning groove of the base plate. The positioning structure also includes a spiral spring, the two free ends of which are fixedly connected to the base plate and the pressure plate, respectively. The pressure plate is provided with a semi-open arc-shaped guide rail, and the pressure plate is rotatably connected to a positioning plate that is adapted to the first limiting post. The guide rail is provided with a slot that matches the positioning plate. The pressure plate is also equipped with a magnetic suction plate, which is magnetically connected to the positioning plate.

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

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

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. A method for preparing a flame-retardant automotive carpet, characterized in that: The steps for preparing the flame-retardant automotive carpet according to claim 3 are as follows: Step 1: Loosen PET fibers and low-melting-point chemical fibers, then sort 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 using a high-speed needle punching machine, and then the surface wear-resistant layer is formed by hot pressing. Step 2: Mix PP fiber, flame retardant, antioxidant and ultraviolet absorber evenly to obtain a mixture. Melt spin the mixture to obtain the fiber material of the flame retardant core layer. Weave the fiber material to obtain the finished flame retardant core layer. Step 3: Using a spraying process, prepare the upper fireproof layer and the lower fireproof layer sequentially on both sides of the flame-retardant core layer; Step 4: Using PET fiber fabric, a porous PET fiber structure is formed through melt spinning. Solvent-free polyurethane foam material is then composite-filled into the porous PET fiber structure, cured until dried, and an elastic layer is produced. Step 5: Lay the layers in the order of "surface wear-resistant layer - flame-retardant composite layer - elastic layer", and then composite them using a roller hot press. After cooling, cut and wrap the edges. Step 6: Install the adhesive backing on the bottom of the elastic layer.

6. The method for preparing a flame-retardant automotive carpet according to claim 5, characterized in that: In step two, the melt spinning temperature is 200~250℃, and the fiber material weaving density is 50~100 threads / cm².

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