Antibacterial and flame-retardant crystal velvet fabric and production method thereof

Abstract

The invention discloses an antibacterial flame-retardant crystal velvet fabric and a production method thereof, and relates to the technical field of crystal velvet fabric manufacturing, the antibacterial flame-retardant crystal velvet fabric comprises a base cloth layer, an antibacterial flame-retardant composite layer and a crystal velvet layer, the antibacterial flame-retardant composite layer is compounded on the upper surface of the base cloth layer, and the crystal velvet layer is compounded on the lower surface of the antibacterial flame-retardant composite layer. The crystal fluff layer is fixed on the surface of the antibacterial flame-retardant composite layer through a hot melt adhesive. By means of the antibacterial flame-retardant composite layer, the silver-loaded montmorillonite releases antibacterial ions, the composite material inhibits flame propagation, the problems that the antibacterial function and the flame-retardant function of the fabric are separated, and durability is poor are solved, the antibacterial effect is improved, and the fabric has high strength and lasting protection performance.

Description

Technical Field

[0001] The invention relates to the technical field of crystal velvet fabric manufacturing, in particular to an antibacterial and flame-retardant crystal velvet fabric and a production method thereof. Background Art

[0002] Crystal velvet is a synthetic fabric with a fine, velvety surface and a bright sheen. It's primarily polyester, with some products blended with a small amount of spandex for added elasticity. Polyester fibers are strong but lack toughness, and frequent friction can easily lead to velvet breakage, clumping, and pilling. Furthermore, the dense velvet surface has poor moisture absorption, making it a breeding ground for bacteria.

[0003] Patent CN110983571B discloses a method for preparing crystal velvet fabric. The above patent achieves a curl shrinkage rate of 31-34% and a curl elastic recovery rate of 79-84% for PBT fiber used for crystal velvet; the stiffness of the crystal velvet fabric is 4.24-5.46 / cm, the thermal resistance is 0.38-0.43K·m2 / W, and the glossiness is 70-75%.

[0004] The aforementioned patent effectively improves fiber curling and fabric physical properties by optimizing PBT fiber processing, offering significant advantages in textile shape retention and thermal comfort. However, as market demand for functional textiles grows, optimizing only physical properties is no longer sufficient to meet the demand for multifunctional material integration in areas such as medical protection and specialty home textiles.

[0005] To this end, the present application proposes an antibacterial and flame-retardant crystal velvet fabric and its production method that can achieve a breakthrough on the basis of maintaining the soft touch and glossiness of traditional crystal velvet by constructing a polyacrylonitrile-based carbon fiber / silver-loaded montmorillonite composite woven layer, a gradient nano antibacterial flame retardant system and a honeycomb microporous-aerogel buffer layer. Summary of the Invention

[0006] The purpose of the present invention is to provide an antibacterial and flame-retardant crystal velvet fabric and a production method thereof, so as to solve the technical problems raised in the above-mentioned background technology that polyester fiber has high strength but insufficient toughness, and frequent friction easily leads to fuzz breakage, agglomeration and pilling. At the same time, the velvet surface is dense, has poor moisture absorption, and is easy to breed bacteria.

[0007] To achieve the above-mentioned object, the present invention provides the following technical solution: an antibacterial and flame-retardant crystal velvet fabric, comprising a base fabric layer, an antibacterial and flame-retardant composite layer, and a crystal velvet layer, wherein the antibacterial and flame-retardant composite layer is composited on the upper surface of the base fabric layer, and the crystal velvet layer is fixed to the surface of the antibacterial and flame-retardant composite layer by a hot-melt adhesive; The antibacterial flame-retardant composite layer is woven from polyacrylonitrile-based carbon fibers and silver-loaded montmorillonite. The carbon fibers have a diameter of 8 to 12 μm, and the silver ion loading of the silver-loaded montmorillonite is 3% to 5%. The antibacterial flame-retardant composite layer is also dispersed with a blend of nano-zinc oxide antibacterial agent and phosphorus-nitrogen flame retardant. The mass ratio of the nano-zinc oxide to the phosphorus-nitrogen flame retardant is 1:3 to 1:5.

[0008] Preferably, the base fabric layer is woven from a blend of modified polyester fiber and flame-retardant polyester fiber, and the flame-retardant polyester fiber accounts for 15% to 25% of the total mass of the base fabric layer; The crystal fleece layer is made of modified PBT fiber, and the surface of the crystal fleece layer is coated with a nano-titanium dioxide / hydroxyapatite composite flame retardant coating; A breathable microporous structure with a pore size of 20 to 50 μm is provided between the base fabric layer and the antibacterial flame-retardant composite layer. A buffer layer is bonded to the bottom of the base fabric layer through a reactive polyurethane adhesive. The molar ratio of the isocyanate group of the reactive polyurethane adhesive to the hydroxyl group on the fiber surface is 1.2:1 to 1.5:1. The buffer layer is composed of a composite of polyurethane foam material and graphene aerogel, with a thickness of 1.5 to 2.5 mm.

[0009] Preferably, the modified polyester fiber is a polyester fiber with a quaternary ammonium salt grafted on the surface, the quaternary ammonium salt grafting amount is 0.8% to 1.5% of the fiber mass, and the initiator is 2,2'-azobisisobutyronitrile; The flame-retardant polyester fiber is a copolyester fiber containing a brominated flame retardant, with a limiting oxygen index ≥28%. The open porosity of the polyurethane foam material is 85% to 95%, the pore diameter is 50 to 150 μm, and the inner wall of the pore is loaded with a nano-zinc oxide and silicon dioxide composite antibacterial agent, with the loading amount being 0.3% to 0.8% of the pore mass.

[0010] Preferably, the particle size of the nano zinc oxide is 20 to 50 nm, and the specific surface area is 50 to 80 m² / g; The phosphorus-nitrogen flame retardant is a compound of ammonium polyphosphate and melamine cyanurate, with a compounding mass ratio of 2:1 to 3:1.

[0011] Preferably, the thickness of the nano-titanium dioxide / hydroxyapatite composite flame retardant coating is 0.8 to 1.5 μm, the mass ratio of nano-titanium dioxide to hydroxyapatite is 1:2 to 1:4, and the silicon dioxide flame retardant coating is doped with nano-silver particles with a mass fraction of 5% to 8% and a particle size of 10 to 30 nm.

[0012] Preferably, the breathable microporous structure is distributed in a honeycomb shape with a porosity of 35% to 45%. The inner wall of the breathable micropores is coated with a chitosan gel layer loaded with a nano-zinc oxide antibacterial agent, with a chitosan concentration of 1% to 2% and a loading mass fraction of 0.5% to 1.0% of nano-zinc oxide particles.

[0013] Preferably, the cross-section of the modified PBT fiber is a composite structure of trilobal and triangular, with trilobal fibers accounting for 60% to 70% and triangular fibers accounting for 30% to 40%, and the fiber single filament fineness is 0.5 to 0.8 dtex.

[0014] Preferably, the hot melt adhesive is a polyurethane adhesive, to which nano-silicon dioxide particles are added at a mass fraction of 5%-10%, a melt index of 20-30 g / 10 min, and a bonding strength of ≥8 N / cm.

[0015] Preferably, the production method further comprises the following steps: S1. Preparation of base fabric layer: Modified polyester fiber and flame-retardant polyester fiber are mixed in a mass ratio of 4:1 to 6:1, vortex-spun into yarn, and knitted into base fabric using a double-sided jacquard machine with a knitting density of 45 to 55 stitches; S2. Antibacterial flame-retardant composite layer coating: Nano-titanium dioxide, hydroxyapatite, nano-zinc oxide and phosphorus-nitrogen flame retardant are dispersed in a water-based polyacrylate emulsion, and silane coupling agent KH-550 is added. After ultrasonic treatment for 30 minutes, a slurry with a solid content of 25% to 30% is formed. The slurry is applied to the surface of the fluff by spraying at a coating amount of 80 to 120 g / m². Subsequently, an aluminum oxide super-hydrophobic film is grown on the coating surface by atomic layer deposition. The precursors are trimethylaluminum and water vapor. The number of cycles is 50, and finally the slurry is dried and solidified at 120 to 140°C. S3. Microporous structure treatment: Laser punching process is used to form honeycomb-shaped breathable micropores at the interface between the base fabric layer and the antibacterial flame retardant composite layer; S4, crystal fleece layer composite: the modified PBT masterbatch is melt-spun into composite cross-section fibers, which are attached to the surface of the antibacterial and flame-retardant composite layer through an electrostatic flocking process. The flocking voltage is 60-80kV and the flocking density is 5000-8000 fibers / cm². After hot pressing at 160-180℃ for 10-15 seconds, the pile and the base fabric are bonded; S5. Flame retardant post-treatment: immerse the composite fabric in a sol-gel solution containing nano-silicon dioxide and nano-silver for 5 to 8 minutes, then cure it in an oven at 150 to 170°C for 20 to 30 minutes to form a surface flame retardant coating; S6. Pre-press the buffer layer to the bottom of the base fabric layer, apply reactive polyurethane adhesive between the base fabric layer, the antibacterial and flame-retardant composite layer and the crystal fleece layer, and laminate them with hot pressing rollers at a roller temperature of 120°C, a pressure of 8 MPa, and a speed of 2 m / min. After lamination, the fabric is subjected to electron beam irradiation by a radiation cross-linking machine with an irradiation dose of 15 kGy.

[0016] Preferably, the production method further comprises the following steps: S51, sol-gel solution is prepared by mixing ethyl orthosilicate, ethanol and silver nitrate in a volume ratio of 10:50:1, adjusting the pH value to 3-4, and aging for 24 hours; The contact angle of the cured coating is ≥150°.

[0017] Compared with the prior art, the present invention has the following beneficial effects: 1. The present invention uses an antibacterial flame-retardant composite layer to achieve the release of antibacterial ions from silver-loaded montmorillonite and the inhibition of flame propagation by the composite material, thus solving the problem of the fabric's poor durability due to the separation of antibacterial and flame-retardant functions. It improves the antibacterial effect and combines high strength with long-lasting protection. 2. This invention uses a modified polyester fiber and flame-retardant polyester blended base fabric layer to achieve microporous breathable cushioning and shock absorption, solving the problems of flame-retardant fabrics being thick, stuffy, and lacking dynamic protection. It improves contact comfort and reduces vertical combustion damage length. 3. This invention achieves water repellency and antifouling by atomic layer deposition of aluminum oxide super-hydrophobic film, solving the problems of easy wear and low flame retardant efficiency of ordinary coatings, increasing the water contact angle and reducing the peak heat release rate; 4. The present invention achieves directional arrangement of pile fastness through electrostatic flocking combined with sol-gel flame retardant treatment, solves the problem of interlayer peeling and functional attenuation caused by multi-process production, and improves production efficiency and fabric peeling strength. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Figure 1 This is a schematic diagram of the fabric production process of the present invention; Figure 2 Schematic diagram of the base fabric layer structure of the present invention; Figure 3 Schematic diagram of the cross-sectional structure of the modified PBT fiber of the present invention; Figure 4 Schematic diagram of the fabric layered structure of the present invention. DETAILED DESCRIPTION

[0019] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.

[0020] Example 1, please refer to Figure 1 、 Figure 2 and Figure 4, an antibacterial and flame-retardant crystal velvet fabric, the production method also includes the following steps: S1, base fabric preparation: modified polyester fiber and flame-retardant polyester fiber are mixed in a mass ratio of 4:1 to 6:1, vortex spinning is used to make yarn, and double-sided jacquard machine is used to weave the base fabric with a weaving density of 45 to 55 needles; S2, antibacterial and flame-retardant composite layer coating: nano titanium dioxide, hydroxyapatite, nano zinc oxide and phosphorus nitrogen flame retardant are dispersed in water-based polyacrylate emulsion, and silane coupling is added. Agent KH-550, after ultrasonic treatment for 30 minutes, a slurry with a solid content of 25% to 30% is formed, which is applied to the surface of the fluff by spraying, with a coating amount of 80 to 120 g / m². Subsequently, an alumina super-hydrophobic film is grown on the coating surface by atomic layer deposition. The precursors are trimethylaluminum and water vapor. The cycle is repeated 50 times, and finally dried and solidified at 120 to 140 ° C. S3, microporous structure treatment: a laser punching process is used to form a microporous structure at the interface between the base fabric layer and the antibacterial flame retardant composite layer. Honeycomb-shaped breathable micropores; S4, crystal fleece layer composite: the modified PBT masterbatch is melt-spun into composite cross-section fibers, which are attached to the surface of the antibacterial flame-retardant composite layer through an electrostatic flocking process. The flocking voltage is 60-80kV and the flocking density is 5000-8000 fibers / cm²; after hot pressing at 160-180℃ for 10-15 seconds, the fleece is bonded to the base fabric; S5, flame-retardant post-treatment: the composite fabric is impregnated with a sol-gel containing nano-silicon dioxide and nano-silver. The gel liquid is immersed for 5 to 8 minutes, and after being taken out, it is cured in an oven at 150 to 170°C for 20 to 30 minutes to form a surface flame retardant coating; S6, the buffer layer is pre-pressed to the bottom of the base fabric layer, and a reactive polyurethane adhesive is applied between the base fabric layer, the antibacterial flame retardant composite layer and the crystal fleece layer, and the composite is laminated with a hot pressing roller at a roller temperature of 120°C, a pressure of 8 MPa, and a speed of 2 m / min. After the composite, the fabric is subjected to electron beam irradiation by a radiation cross-linking machine at an irradiation dose of 15 kGy; The production method further includes the following steps: S51, the sol-gel solution is mixed with ethyl orthosilicate, ethanol, and silver nitrate in a volume ratio of 10:50:1, the pH value is adjusted to 3-4, and the aging is carried out for 24 hours; after curing, the contact angle of the coating is ≥150°.

[0021] Furthermore, the base fabric layer is a blend of modified polyester fiber and flame-retardant polyester fiber in a mass ratio of 5:1, the flame-retardant polyester fiber accounts for 20% of the total mass of the base fabric layer, and the weaving density is 50 stitches; the surface of the modified polyester fiber is grafted with quaternary ammonium salt, the grafting amount is 1.2%, and the initiator is 2,2'-azobisisobutyronitrile; the flame-retardant polyester fiber contains a brominated flame retardant, and the limiting oxygen index is 30%; the antibacterial flame retardant composite layer is a composite weaving of polyacrylonitrile-based carbon fiber with a diameter of 10μm and silver-loaded montmorillonite with a silver ion loading of 4%, a dispersed particle size of 30nm, a specific surface area of 60m² / g, and a phosphorus-nitrogen flame retardant, with a mass ratio of 1: 4. The phosphorus-nitrogen flame retardant is a blend of ammonium polyphosphate and melamine cyanurate in a mass ratio of 2.5:1. The crystal fleece layer is a modified PBT fiber with a trilobal:triangular ratio of 65:35, a single-filament fineness of 0.6 dtex, and a surface coated with a nano-titanium dioxide / hydroxyapatite composite flame retardant coating with a thickness of 1.2 μm and a mass ratio of 1:3, doped with 6% 20 nm nanosilver particles. The base fabric and the composite layer have honeycomb-shaped breathable micropores, and the inner wall is coated with 1.5% chitosan gel. The buffer layer is a composite of polyurethane foam and graphene aerogel, bonded with a reactive polyurethane adhesive. Modified polyester fiber and flame-retardant polyester fiber were mixed at a ratio of 5:1, vortex-spun and woven on a double-sided jacquard machine with a density of 50 needles. Nano-titanium dioxide, hydroxyapatite, nano-zinc oxide, and phosphorus-nitrogen flame retardant were dispersed in a water-based polyacrylate emulsion, and silane coupling agent KH-550 was added. The slurry with a solid content of 28% was prepared by ultrasonic treatment for 30 minutes. The slurry was sprayed on the surface of the fleece, and an atomic layer deposition aluminum oxide film was applied. The slurry was dried and solidified at 130°C. Honeycomb micropores with a pore size of 35 μm were formed by laser drilling. The porosity is 40%, and the inner surface is coated with 1.5% chitosan gel. The composite cross-section fiber is melt-spun from modified PBT masterbatch, electrostatically flocked, hot-pressed at 170°C for 12 seconds, and bonded with a hot-melt adhesive. It is then impregnated with a sol-gel solution of 10:50:1 ethyl orthosilicate: ethanol: silver nitrate for 6 minutes and cured at 160°C for 25 minutes, achieving a contact angle of 155°. A buffer layer is pre-pressed onto the bottom of the base fabric, and a reactive polyurethane adhesive is applied. The composite cross-section fiber is then hot-pressed and rolled, and electron beam irradiated to 15 kGy. According to GB / T20944.3-2008 test, Staphylococcus aureus and Escherichia coli were selected as test bacteria. The fabric was cut into 5cm×5cm samples and placed in a conical flask containing 10mL sterile saline. The concentration of the inoculated bacteria was 1×10 51 mL of a bacterial suspension containing 100 CFU / mL was shaken at 150 rpm in a 37°C constant temperature shaking incubator for 18 hours. After the incubation period, the shaken solution was diluted and inoculated onto nutrient agar medium using the pour method. After incubation at 37°C for 24 hours, the colonies were counted. The inhibition rate was calculated using the formula "Inhibition rate (%) = (number of colonies in the control sample - number of colonies in the test sample) / number of colonies in the control sample × 100%." The results showed that the inhibition rate for Escherichia coli in Example 1 reached 99.9%, and the inhibition rate for Staphylococcus aureus was 99.8%.

[0022] Example 2, please refer to Figure 1 、 Figure 2 、 Figure 3 and Figure 4 An antibacterial and flame-retardant crystal velvet fabric comprises a base fabric layer, an antibacterial and flame-retardant composite layer, and a crystal velvet layer. The antibacterial and flame-retardant composite layer is composited on the upper surface of the base fabric layer, and the crystal velvet layer is fixed to the surface of the antibacterial and flame-retardant composite layer by a hot-melt adhesive. The antibacterial and flame-retardant composite layer is woven from polyacrylonitrile-based carbon fibers and silver-loaded montmorillonite. The carbon fibers have a diameter of 8 to 12 μm, and the silver ion loading of the silver-loaded montmorillonite is 3% to 5%. The antibacterial and flame-retardant composite layer is further dispersed with a blend of nano-zinc oxide antibacterial agent and phosphorus-nitrogen flame retardant. The mass ratio of nano-zinc oxide to phosphorus-nitrogen flame retardant is 1:3 to 1:5. The nano zinc oxide has a particle size of 20 to 50 nm and a specific surface area of 50 to 80 m² / g; the phosphorus-nitrogen flame retardant is a compound of ammonium polyphosphate and melamine cyanurate, with a compounding mass ratio of 2:1 to 3:1; Furthermore, the base fabric layer is a blend of modified polyester fiber and flame-retardant polyester fiber in a mass ratio of 5:1, the flame-retardant polyester fiber accounts for 25% of the total mass of the base fabric layer, and the weaving density is 45 stitches; the surface of the modified polyester fiber is grafted with quaternary ammonium salt, the grafting amount is 1.2%, and the initiator is 2,2'-azobisisobutyronitrile; the flame-retardant polyester fiber contains a brominated flame retardant, and the limiting oxygen index is 30%; the antibacterial flame retardant composite layer is a composite weaving of polyacrylonitrile-based carbon fiber with a diameter of 10μm and silver-loaded montmorillonite with a silver ion loading of 4%, a dispersed particle size of 30nm, a specific surface area of 60m² / g, and a phosphorus-nitrogen flame retardant, the mass ratio of which is 1: 4. The phosphorus-nitrogen flame retardant is a blend of ammonium polyphosphate and melamine cyanurate in a mass ratio of 2.5:1. The crystal fleece layer is a modified PBT fiber with a trilobal:triangular ratio of 65:35, a single-filament fineness of 0.6 dtex, and a surface coated with a nano-titanium dioxide / hydroxyapatite composite flame retardant coating with a thickness of 1.2 μm and a mass ratio of 1:3, doped with 6% 20 nm nanosilver particles. The base fabric and the composite layer have honeycomb-shaped breathable micropores, and the inner wall is coated with 1.5% chitosan gel. The buffer layer is a composite of polyurethane foam and graphene aerogel, bonded with a reactive polyurethane adhesive. Modified polyester fiber and flame-retardant polyester fiber were mixed at a ratio of 4:1, vortex-spun and woven on a double-sided jacquard machine with a density of 45 needles. Nano-titanium dioxide, hydroxyapatite, nano-zinc oxide, and phosphorus-nitrogen flame retardant were dispersed in a water-based polyacrylate emulsion, and silane coupling agent KH-550 was added. The slurry with a solid content of 28% was prepared by ultrasonic treatment for 30 minutes. The slurry was sprayed on the surface of the fleece, and an atomic layer deposition aluminum oxide film was applied. The slurry was dried and solidified at 130°C. Honeycomb micropores with a pore size of 35 μm were formed by laser drilling. The porosity is 40%, and the inner surface is coated with 1.5% chitosan gel. The composite cross-section fiber is melt-spun from modified PBT masterbatch, electrostatically flocked, hot-pressed at 170°C for 12 seconds, and bonded with a hot-melt adhesive. It is then impregnated with a sol-gel solution of 10:50:1 ethyl orthosilicate: ethanol: silver nitrate for 6 minutes and cured at 160°C for 25 minutes, achieving a contact angle of 155°. A buffer layer is pre-pressed onto the bottom of the base fabric, and a reactive polyurethane adhesive is applied. The composite cross-section fiber is then hot-pressed and rolled, and electron beam irradiated to 15 kGy. According to the test of GB / T17591-2018, the vertical combustion method was used to test the fabrics of Example 1 and Example 2. The fabric was cut into 300mm×75mm samples, fixed vertically on the test stand, and a Bunsen burner with a flame height of 40mm was used to apply flame to the center of the bottom edge of the sample for 12 seconds and then removed. The afterburning time, smoldering time and damaged length of the sample were recorded. The afterburning time of Example 1 was 0 seconds, the smoldering time was 1.5 seconds, and the damaged length was less than 100mm, meeting the B1 flame retardant standard; Example 2 increased the proportion of flame retardant polyester fiber in the base cloth, and the limiting oxygen index was increased from 28.8% to 29.5%, and the vertical combustion smoldering time was shortened to 1.2 seconds, further proving the synergistic effect of flame retardant and fiber on the improvement of flame retardant properties.

[0023] Example 3, please refer to Figure 1 、 Figure 2 、 Figure 3 and Figure 4 An antibacterial and flame-retardant crystal velvet fabric. The base fabric layer is woven from a blend of modified polyester fiber and flame-retardant polyester fiber, with the flame-retardant polyester fiber accounting for 15% to 25% of the total mass of the base fabric layer. The crystal fleece layer is composed of modified PBT fiber, and the surface of the crystal fleece layer is coated with a nano-titanium dioxide / hydroxyapatite composite flame-retardant coating. A breathable microporous structure with a pore size of 20 to 50 μm is provided between the base fabric layer and the antibacterial and flame-retardant composite layer. A buffer layer is bonded to the bottom of the base fabric layer with a reactive polyurethane adhesive. The molar ratio of the isocyanate group of the reactive polyurethane adhesive to the hydroxyl group on the fiber surface is 1.2:1 to 1.5:1. The buffer layer is composed of a composite of polyurethane foam material and graphene aerogel, and has a thickness of 1.5 to 2.5 mm. The modified polyester fiber is a polyester fiber with a quaternary ammonium salt grafted on the surface, the quaternary ammonium salt grafting amount is 0.8% to 1.5% of the fiber mass, and the initiator is 2,2'-azobisisobutyronitrile; the flame-retardant polyester fiber is a copolyester fiber containing a brominated flame retardant, the limiting oxygen index is ≥28%, the open porosity of the polyurethane foam material is 85% to 95%, the pore diameter is 50 to 150 μm, and the inner wall of the pore is loaded with a nano-zinc oxide and silicon dioxide composite antibacterial agent, the loading amount of which is 0.3% to 0.8% of the pore mass; Furthermore, the base fabric layer is a blend of modified polyester fiber and flame-retardant polyester fiber in a mass ratio of 5:1, the flame-retardant polyester fiber accounts for 20% of the total mass of the base fabric layer, and the weaving density is 50 stitches; the surface of the modified polyester fiber is grafted with quaternary ammonium salt, the grafting amount is 1.2%, and the initiator is 2,2'-azobisisobutyronitrile; the flame-retardant polyester fiber contains a brominated flame retardant, and the limiting oxygen index is 30%; the antibacterial flame retardant composite layer is a composite weaving of polyacrylonitrile-based carbon fiber with a diameter of 10μm and silver-loaded montmorillonite with a silver ion loading of 4%, a dispersed particle size of 30nm, a specific surface area of 60m² / g, and a phosphorus-nitrogen flame retardant, with a mass ratio of 1: 3. The phosphorus-nitrogen flame retardant is a blend of ammonium polyphosphate and melamine cyanurate in a mass ratio of 2.5:1. The crystal fleece layer is a modified PBT fiber with a trilobal:triangular ratio of 65:35 and a single-filament fineness of 0.6 dtex. The surface is coated with a nano-titanium dioxide / hydroxyapatite composite flame retardant coating with a thickness of 1.2 μm and a mass ratio of 1:3, doped with 8% 20 nm nanosilver particles. The base fabric and the composite layer have honeycomb-shaped breathable micropores, and the inner wall is coated with 1.5% chitosan gel. The buffer layer is a composite of polyurethane foam and graphene aerogel, bonded with a reactive polyurethane adhesive. Modified polyester fiber and flame-retardant polyester fiber were mixed at a ratio of 5:1, vortex-spun and woven on a double-sided jacquard machine with a density of 50 needles. Nano-titanium dioxide, hydroxyapatite, nano-zinc oxide, and phosphorus-nitrogen flame retardant were dispersed in a water-based polyacrylate emulsion, and silane coupling agent KH-550 was added. The slurry with a solid content of 28% was prepared by ultrasonic treatment for 30 minutes. The slurry was sprayed on the surface of the fleece, and an atomic layer deposition aluminum oxide film was applied. The slurry was dried and solidified at 130°C. Honeycomb micropores with a pore size of 35 μm were formed by laser drilling. The porosity is 40%, and the inner wall is coated with 1.5% chitosan gel. The composite cross-section fiber is made by melt spinning modified PBT masterbatch, electrostatic flocking, hot pressing at 170°C for 12 seconds, and bonding with hot melt adhesive. It is impregnated with a sol-gel solution of ethyl orthosilicate: ethanol: silver nitrate = 10:50:1 for 30 hours, and cured at 160°C for 15 seconds, with a contact angle of 155°. A buffer layer is pre-pressed to the bottom of the base fabric, and a reactive polyurethane adhesive is applied. It is hot-pressed and rolled, and electron beam irradiated to 15kGy. According to GB / T20944.3-2008 test, Staphylococcus aureus and Escherichia coli were selected as test bacteria. The fabric was cut into 5cm×5cm samples and placed in a conical flask containing 10mL sterile saline. The concentration of the inoculated bacteria was 1×105 1 mL of bacterial suspension with a CFU / mL was shaken at 150 r / min in a constant temperature shaking incubator at 37°C for 18 hours. After the incubation, the shaken liquid was diluted and inoculated onto nutrient agar medium using the pouring method. The number of colonies was counted after incubation at 37°C for 24 hours. The inhibition rate was calculated using the formula "Inhibition rate (%) = (number of colonies in the control sample - number of colonies in the test sample) / number of colonies in the control sample × 100%". The results showed that the inhibition rate of Escherichia coli in Example 3 reached 99.9%, and the inhibition rate of Staphylococcus aureus was increased to 99.9%.

[0024] Example 4, please refer to Figure 1 、 Figure 2 、 Figure 3 and Figure 4 An antibacterial and flame-retardant crystal velvet fabric, wherein the thickness of the nano-titanium dioxide / hydroxyapatite composite flame-retardant coating is 0.8 to 1.5 μm, the mass ratio of nano-titanium dioxide to hydroxyapatite is 1:2 to 1:4, and the silicon dioxide flame-retardant coating is doped with 5% to 8% by mass of nano-silver particles with a particle size of 10 to 30 nm; The air-permeable microporous structure is distributed in a honeycomb shape, with a porosity of 35% to 45%. The inner wall of the air-permeable microporous structure is coated with a chitosan gel layer loaded with a nano-zinc oxide antibacterial agent, with a chitosan concentration of 1% to 2% and a loading mass fraction of 0.5% to 1.0% of nano-zinc oxide particles. Furthermore, the base fabric layer is a blend of modified polyester fiber and flame-retardant polyester fiber in a mass ratio of 5:1, the flame-retardant polyester fiber accounts for 20% of the total mass of the base fabric layer, and the weaving density is 50 stitches; the surface of the modified polyester fiber is grafted with quaternary ammonium salt, the grafting amount is 1.2%, and the initiator is 2,2'-azobisisobutyronitrile; the flame-retardant polyester fiber contains a brominated flame retardant, and the limiting oxygen index is 30%; the antibacterial flame retardant composite layer is a composite weaving of polyacrylonitrile-based carbon fiber with a diameter of 10μm and silver-loaded montmorillonite with a silver ion loading of 4%, a dispersed particle size of 30nm, a specific surface area of 60m² / g, and a phosphorus-nitrogen flame retardant, with a mass ratio of 1: 4. The phosphorus-nitrogen flame retardant is a blend of ammonium polyphosphate and melamine cyanurate in a mass ratio of 2.5:1. The crystal fleece layer is a modified PBT fiber with a trilobal:triangular ratio of 70:30, a single-filament fineness of 0.5 dtex, and a surface coated with a nano-titanium dioxide / hydroxyapatite composite flame retardant coating with a thickness of 1.2 μm and a mass ratio of 1:3, doped with 6% 20 nm nanosilver particles. The base fabric and the composite layer have honeycomb-shaped breathable micropores, and the inner wall is coated with 1.5% chitosan gel. The buffer layer is a composite of polyurethane foam and graphene aerogel, bonded with a reactive polyurethane adhesive. Modified polyester fiber and flame retardant polyester fiber were mixed at a ratio of 5:1, vortex-spun and woven on a double-sided jacquard machine with a density of 50 needles; nano-titanium dioxide, hydroxyapatite, nano-zinc oxide and phosphorus-nitrogen flame retardant were dispersed in water-based polyacrylate emulsion, silane coupling agent KH-550 was added, and ultrasonic treatment was performed for 30 minutes to prepare a slurry with a solid content of 28%, which was sprayed on the surface of the fluff, and an atomic layer deposition aluminum oxide film was applied, which was dried and solidified at 130℃; honeycomb micropores were formed by laser drilling with a pore size of 50μm and a porosity of 45%, and the inner wall was coated with 2% chitosan gel. The composite cross-section fiber was prepared by melt spinning modified PBT masterbatch, electrostatically flocked, hot-pressed at 170°C for 12 seconds, and bonded with a hot-melt adhesive. The fiber was then impregnated with a sol-gel solution of 10:50:1 ethyl orthosilicate: ethanol: silver nitrate for 6 minutes and cured at 160°C for 25 minutes, achieving a contact angle of 155°. A buffer layer was pre-pressed onto the base fabric, and a reactive polyurethane adhesive was applied. The fiber was then hot-rolled and composited. Electron beam irradiation was performed at 15 kGy. The laser drilling power was increased by 10%, and the microporous inner wall coating treatment time was increased by 5 minutes. Testing was conducted in accordance with GB / T5453-1997 using a YG461E fabric air permeability tester. The fabrics from Examples 1 and 4 were cut into circular specimens with a diameter of 7 cm and fixed to the test holes of the air permeability tester. The air flow rate through the fabric per unit time was measured under a pressure differential of 100 Pa. The air permeability of Example 1 was 25 L / (m²·s); in Example 4, the air permeability was increased to 32 L / (m²·s) by increasing the pore size to 50 μm and the porosity to 45%.

[0025] Example 5, please refer to Figure 1 、 Figure 2 、 Figure 3 and Figure 4 , an antibacterial and flame-retardant crystal velvet fabric, wherein the cross-section of the modified PBT fiber is a composite structure of trilobal and triangular shapes, with trilobal fibers accounting for 60% to 70% and triangular fibers accounting for 30% to 40%, and the fiber monofilament fineness is 0.5 to 0.8 dtex; The hot melt adhesive is a polyurethane adhesive, to which 5% to 10% by mass of nano-silicon dioxide particles are added, the melt index is 20 to 30 g / 10 min, and the bonding strength is ≥8 N / cm Furthermore, the base fabric layer is a blend of modified polyester fiber and flame-retardant polyester fiber in a mass ratio of 5:1, the flame-retardant polyester fiber accounts for 20% of the total mass of the base fabric layer, and the weaving density is 50 stitches; the surface of the modified polyester fiber is grafted with quaternary ammonium salt, the grafting amount is 1.2%, and the initiator is 2,2'-azobisisobutyronitrile; the flame-retardant polyester fiber contains a brominated flame retardant, and the limiting oxygen index is 30%; the antibacterial flame retardant composite layer is a composite weaving of polyacrylonitrile-based carbon fiber with a diameter of 10μm and silver-loaded montmorillonite with a silver ion loading of 4%, a dispersed particle size of 30nm, a specific surface area of 60m² / g, and a phosphorus-nitrogen flame retardant, with a mass ratio of 1: 4. The phosphorus-nitrogen flame retardant is a blend of ammonium polyphosphate and melamine cyanurate in a mass ratio of 2.5:1. The crystal fleece layer is a modified PBT fiber with a trilobal:triangular ratio of 65:35, a single-filament fineness of 0.6 dtex, and a surface coated with a nano-titanium dioxide / hydroxyapatite composite flame retardant coating with a thickness of 1.2 μm and a mass ratio of 1:3, doped with 6% 20 nm nanosilver particles. The base fabric and the composite layer have honeycomb-shaped breathable micropores, and the inner wall is coated with 1.5% chitosan gel. The buffer layer is a composite of polyurethane foam and graphene aerogel, bonded with a reactive polyurethane adhesive. Modified polyester fiber and flame-retardant polyester fiber were mixed at a ratio of 5:1, vortex-spun and woven on a double-sided jacquard machine with a density of 50 needles; nano-titanium dioxide, hydroxyapatite, nano-zinc oxide, and phosphorus-nitrogen flame retardant were dispersed in a water-based polyacrylate emulsion, and silane coupling agent KH-550 was added. The slurry with a solid content of 28% was prepared by ultrasonication for 30 minutes, and then sprayed on the surface of the fluff. Aluminum oxide film was deposited by atomic layer deposition and dried at 130°C for curing; honeycomb micropores were formed by laser drilling with a pore size of 35 μm and a pore size of 10 μm. The porosity is 40%, and the inner wall is coated with 1.5% chitosan gel. The composite cross-section fiber is made by melt spinning modified PBT masterbatch, electrostatic flocking, hot pressing at 170°C for 12 seconds, and bonding with hot melt adhesive. It is impregnated with a sol-gel solution of 10:50:1 ethyl orthosilicate: ethanol: silver nitrate for 6 minutes, and cured at 160°C for 25 minutes, with a contact angle of 155°. A buffer layer is pre-pressed to the bottom of the base fabric, and a reactive polyurethane adhesive is applied. The composite cross-section fiber is then hot-pressed and rolled, and the electron beam irradiation dose is 12 kGy. The flame-retardant polyester fiber was replaced with a halogen-free, phosphorus-based flame-retardant fiber. The phosphorus-nitrogen flame retardant was an ammonium polyphosphate:melamine cyanurate ratio of 3:1. The polyurethane foam material in the buffer layer was loaded with 0.5% nano-zinc oxide / silicon dioxide composite antibacterial agent. The pH of the sol-gel solution was adjusted to 4 and aged for 24 hours. The smoke density chamber method was used. The fabric sample was placed in a sealed chamber and ignited. The degree of light obstruction caused by the smoke during combustion was measured using a photoelectric system. The maximum smoke density value was used to evaluate the smoke emission. The maximum smoke density value was 35, which was lower than the 45 in Example 1.

[0026] Comparative Example 1: Base fabric layer: modified polyester fiber surface grafted with quaternary ammonium salt, grafting weight 1.2%, initiator 2,2'-azobisisobutyronitrile; crystal fleece layer: modified PBT fiber with a trilobal:triangular ratio of 65:35 and a single filament fineness of 0.6 dtex; honeycomb-shaped breathable micropores between the base fabric and the composite layer, and a 1.5% chitosan gel coating on the inner wall; the buffer layer is a composite of polyurethane foam material and graphene aerogel, and the base fabric layer is directly bonded to the crystal fleece layer with a conventional adhesive; Modified polyester fibers were vortex-spun and woven on a double-sided jacquard machine with a density of 50 needles. Nano-titanium dioxide and hydroxyapatite were dispersed in a water-based polyacrylate emulsion, and a silane coupling agent, KH-550, was added. The mixture was ultrasonically treated for 30 minutes to prepare a 28% solid content slurry, which was sprayed on the surface of the fleece. Aluminum oxide film was deposited by atomic layer deposition and dried at 130°C for curing. Honeycomb micropores with a pore size of 35 μm and a porosity of 40% were formed by laser drilling. The inner wall was coated with 1.5% chitosan gel. Modified PBT masterbatch was melt-spun to produce composite cross-section fibers, which were electrostatically flocked, hot-pressed at 170°C for 12 seconds, and bonded with hot-melt adhesive. The fibers were impregnated with a sol-gel solution of 10:50:1 of tetraethyl orthosilicate, ethanol, and silver nitrate for 6 minutes and cured at 160°C for 25 minutes, with a contact angle of 155°. A buffer layer was pre-pressed onto the bottom of the base fabric, and a reactive polyurethane adhesive was applied. The fibers were hot-pressed and composited with a roller, and electron beam irradiated to 15 kGy. According to GB / T20944.3-2008 test, Staphylococcus aureus and Escherichia coli were selected as test bacteria. The fabric was cut into 5cm×5cm samples and placed in a conical flask containing 10mL sterile saline. The concentration of the inoculated bacteria was 1×10 5 1 mL of a bacterial suspension containing 100 CFU / mL was incubated in a 37°C shaking incubator at 150 rpm for 18 hours. The suspension was diluted and inoculated onto nutrient agar using the pour method. After incubation at 37°C for 24 hours, the colonies were counted. The inhibition rate was calculated using the formula: "Inhibition rate (%) = (number of colonies in the control sample - number of colonies in the test sample) / number of colonies in the control sample × 100%." The results showed that the E. coli inhibition rate in Comparative Example 1 reached 65%, resulting in a flame retardancy rating of 0.

[0027] Working Principle: First, the antibacterial flame-retardant composite layer forms a physical barrier through the rigid framework of polyacrylonitrile-based carbon fibers. The high thermal conductivity of carbon fibers quickly dissipates heat. Silver-loaded montmorillonite slowly releases silver ions, expanding at high temperatures to form a thermal barrier. Nano-zinc oxide photocatalytically generates reactive oxygen species that destroy bacterial cell membranes. The phosphorus-nitrogen flame retardant decomposes upon heating to form a polyphosphate coating that isolates oxygen while releasing nitrogen to dilute combustible gases, forming a synergistic flame-retardant system.

[0028] The modified polyester fiber in the base fabric layer then undergoes surface grafting with quaternary ammonium salts, disrupting bacterial charge balance and providing antibacterial properties. The brominated flame retardant in the flame-retardant polyester fiber generates free radical scavengers during combustion, interrupting the chain reaction. The honeycomb arrangement of the breathable microporous structure accelerates heat dissipation through air convection, while the nano-zinc oxide in the chitosan gel layer enhances the antibacterial properties of the pore walls. The trilobal-triangular composite cross-section of the crystal fleece layer creates a light-reflecting effect, reducing thermal radiation absorption. The nano-titanium dioxide / hydroxyapatite coating achieves surface flame retardancy through the endothermic decomposition of hydroxyapatite and the UV shielding of titanium dioxide.

[0029] Finally, the polyurethane foam material in the buffer layer absorbs impact energy through its high-porosity structure, while the three-dimensional graphene aerogel network provides elastic support. During the production process, the super-hydrophobic aluminum oxide film formed by atomic layer deposition reduces the surface energy of the fabric, enabling self-cleaning. Electron beam irradiation triggers the graft polymerization of isocyanate groups in the polyurethane adhesive onto the fiber hydroxyl groups, forming covalent bonds that enhance interfacial bonding. The nano-silica / silver composite coating, constructed using the sol-gel method, enhances flame retardancy and durability through the thermal stability of the silicon-oxygen network, while the plasmon resonance effect of the nano-silver particles enhances the antimicrobial spectrum.

[0030] 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 embodied in other specific forms without departing from the spirit or essential characteristics of the invention. Therefore, the embodiments should be considered in all respects as illustrative and non-restrictive, and the scope of the invention is defined by the appended claims, not the foregoing description, and all variations within the meaning and range of equivalents of the claims are intended to be included therein. Any reference sign in a claim should not be construed as limiting the claim to which it relates.

Claims

1. An antibacterial and flame-retardant crystal velvet fabric, characterized by: It comprises a base fabric layer, an antibacterial flame retardant composite layer and a crystal fleece layer, wherein the antibacterial flame retardant composite layer is composited on the upper surface of the base fabric layer, and the crystal fleece layer is fixed to the surface of the antibacterial flame retardant composite layer by a hot melt adhesive; The antibacterial flame-retardant composite layer is woven from polyacrylonitrile-based carbon fibers and silver-loaded montmorillonite. The carbon fibers have a diameter of 8 to 12 μm, and the silver ion loading of the silver-loaded montmorillonite is 3% to 5%. The antibacterial flame-retardant composite layer is also dispersed with a blend of nano-zinc oxide antibacterial agent and phosphorus-nitrogen flame retardant. The mass ratio of the nano-zinc oxide to the phosphorus-nitrogen flame retardant is 1:3 to 1:

5.

2. The antibacterial and flame-retardant crystal velvet fabric according to claim 1, characterized in that: The base fabric layer is woven from a blend of modified polyester fiber and flame-retardant polyester fiber, wherein the flame-retardant polyester fiber accounts for 15% to 25% of the total mass of the base fabric layer; The crystal fleece layer is made of modified PBT fiber, and the surface of the crystal fleece layer is coated with a nano-titanium dioxide / hydroxyapatite composite flame retardant coating; A breathable microporous structure with a pore size of 20 to 50 μm is provided between the base fabric layer and the antibacterial flame-retardant composite layer. A buffer layer is bonded to the bottom of the base fabric layer through a reactive polyurethane adhesive. The molar ratio of the isocyanate group of the reactive polyurethane adhesive to the hydroxyl group on the fiber surface is 1.2:1 to 1.5:

1. The buffer layer is composed of a composite of polyurethane foam material and graphene aerogel, with a thickness of 1.5 to 2.5 mm.

3. The antibacterial and flame-retardant crystal velvet fabric according to claim 2, characterized in that: The modified polyester fiber is a polyester fiber with a quaternary ammonium salt grafted on the surface, the quaternary ammonium salt grafting amount is 0.8% to 1.5% of the fiber mass, and the initiator is 2,2'-azobisisobutyronitrile; The flame-retardant polyester fiber is a copolyester fiber containing a brominated flame retardant, with a limiting oxygen index ≥28%. The open porosity of the polyurethane foam material is 85% to 95%, the pore diameter is 50 to 150 μm, and the inner wall of the pore is loaded with a nano-zinc oxide and silicon dioxide composite antibacterial agent, with the loading amount being 0.3% to 0.8% of the pore mass.

4. The antibacterial and flame-retardant crystal velvet fabric according to claim 1, characterized in that: The particle size of the nano zinc oxide is 20 to 50 nm, and the specific surface area is 50 to 80 m² / g; The phosphorus-nitrogen flame retardant is a compound of ammonium polyphosphate and melamine cyanurate, with a compounding mass ratio of 2:1 to 3:

1.

5. The antibacterial and flame-retardant crystal velvet fabric according to claim 2, characterized in that: The thickness of the nano titanium dioxide / hydroxyapatite composite flame retardant coating is 0.8 to 1.5 μm, the mass ratio of nano titanium dioxide to hydroxyapatite is 1:2 to 1:4, and the silicon dioxide flame retardant coating is doped with nano silver particles with a mass fraction of 5% to 8% and a particle size of 10 to 30 nm.

6. The antibacterial and flame-retardant crystal velvet fabric according to claim 2, characterized in that: The breathable microporous structure is distributed in a honeycomb shape with a porosity of 35% to 45%. The inner wall of the breathable micropores is coated with a chitosan gel layer loaded with a nano-zinc oxide antibacterial agent, with a chitosan concentration of 1% to 2% and a loading mass fraction of 0.5% to 1.0% of nano-zinc oxide particles.

7. The antibacterial and flame-retardant crystal velvet fabric according to claim 2, characterized in that: The cross section of the modified PBT fiber is a composite structure of trilobal and triangular shapes, with trilobal fibers accounting for 60% to 70% and triangular fibers accounting for 30% to 40%. The fiber single filament fineness is 0.5 to 0.8 dtex.

8. The antibacterial and flame-retardant crystal velvet fabric according to claim 1, characterized in that: The hot melt adhesive is a polyurethane adhesive, to which nano-silicon dioxide particles are added in a mass fraction of 5%-10%, a melt index of 20-30g / 10min, and a bonding strength of ≥8N / cm.

9. A method for producing antibacterial and flame-retardant crystal velvet fabric, applicable to the antibacterial and flame-retardant crystal velvet fabric according to any one of claims 1 to 8, characterized in that: The production method further comprises the following steps: S1. Preparation of base fabric layer: Modified polyester fiber and flame-retardant polyester fiber are mixed in a mass ratio of 4:1 to 6:1, vortex-spun into yarn, and knitted into base fabric using a double-sided jacquard machine with a knitting density of 45 to 55 stitches; S2. Antibacterial flame-retardant composite layer coating: Nano-titanium dioxide, hydroxyapatite, nano-zinc oxide and phosphorus-nitrogen flame retardant are dispersed in a water-based polyacrylate emulsion, and silane coupling agent KH-550 is added. After ultrasonic treatment for 30 minutes, a slurry with a solid content of 25% to 30% is formed. The slurry is applied to the surface of the fluff by spraying at a coating amount of 80 to 120 g / m². Subsequently, an aluminum oxide super-hydrophobic film is grown on the coating surface by atomic layer deposition. The precursors are trimethylaluminum and water vapor. The number of cycles is 50, and finally the slurry is dried and solidified at 120 to 140°C. S3. Microporous structure treatment: Laser punching process is used to form honeycomb-shaped breathable micropores at the interface between the base fabric layer and the antibacterial flame retardant composite layer; S4, crystal fleece layer composite: the modified PBT masterbatch is melt-spun into composite cross-section fibers, which are attached to the surface of the antibacterial and flame-retardant composite layer through an electrostatic flocking process. The flocking voltage is 60-80kV and the flocking density is 5000-8000 fibers / cm². After hot pressing at 160-180℃ for 10-15 seconds, the pile and the base fabric are bonded; S5. Flame retardant post-treatment: immerse the composite fabric in a sol-gel solution containing nano-silicon dioxide and nano-silver for 5 to 8 minutes, then cure it in an oven at 150 to 170°C for 20 to 30 minutes to form a surface flame retardant coating; S6. Pre-press the buffer layer to the bottom of the base fabric layer, apply reactive polyurethane adhesive between the base fabric layer, the antibacterial and flame-retardant composite layer and the crystal fleece layer, and laminate them with hot pressing rollers at a roller temperature of 120°C, a pressure of 8 MPa, and a speed of 2 m / min. After lamination, the fabric is subjected to electron beam irradiation by a radiation cross-linking machine with an irradiation dose of 15 kGy.

10. The method for producing antibacterial and flame-retardant crystal velvet fabric according to claim 9, characterized in that: The production method further comprises the following steps: S51, sol-gel solution is prepared by mixing ethyl orthosilicate, ethanol and silver nitrate in a volume ratio of 10:50:1, adjusting the pH value to 3-4, and aging for 24 hours; The contact angle of the cured coating is ≥150°.

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