Preparation method of insulating flame-retardant automotive interior microfiber material

Abstract

The invention relates to the technical field of microfiber material preparation, in particular to a preparation method of an insulating flame-retardant automotive interior microfiber material, which comprises the following steps: spinning sea-island fibers by taking PA6 as an island component and LDPE as a sea component and matching with master batches; performing opening, carding, lapping, pre-needling by a pre-needling machine and needling by a needling machine on the sea-island fibers to prepare non-woven fabric; carrying out heat setting on the non-woven fabric; preparing insulating flame-retardant polyurethane slurry, infiltrating the heat-set non-woven fabric to enable the non-woven fabric to be fully impregnated, and then feeding the non-woven fabric into an aqueous solution of dimethylformamide to be subjected to water bath curing, so as to prepare a semi-finished synthetic leather product; extracting sea components in the sea-island fibers from the synthetic leather semi-finished product by adopting a stripping process; and drying the reduced superfine fiber synthetic leather base cloth, immersing the base cloth into a softening agent aqueous solution, and then carrying out drying and leather rubbing treatment to obtain the insulating flame-retardant superfine fiber leather. The product provided by the invention is used for external protection of an intelligent auxiliary driving steering wheel sensing layer, and the resistance of the microfiber material reaches 1.2 megohm or above.

Description

Technical Field

[0001] The present invention relates to the technical field of ultra-fiber material preparation, and in particular to a method for preparing an insulating and flame-retardant ultra-fiber material for automobile interior decoration. Background Art

[0002] With the continuous innovation of automobile manufacturing technology and the continuous upgrading of intelligent features such as smart driving and health monitoring, ultra-fiber materials have been developed for parts such as automobile steering wheels as covering materials to realize the HOD function of autonomous driving to avoid potential dangerous situations.

[0003] This coating is used for smart driving capacitive steering wheels, preventing microcurrent interference caused by the capacitive sensing pad. Capacitive steering wheels provide more accurate finger recognition. The capacitive sensing steering wheel structure consists of an outer coating, a dual-zone capacitive sensing pad, an insulating layer, a PU heating layer, an internal foam material, and a frame.

[0004] Because conventional microfiber leather has a low resistance value, there will be microcurrent when using the capacitive steering wheel, which will affect the judgment of the sensor, cause misjudgment, and thus affect the driving experience. Summary of the Invention

[0005] In order to solve the defects in the prior art, the present invention provides a method for preparing an insulating flame-retardant microfiber material for automotive interior decoration, which is specifically achieved through the following technical solutions: A method for preparing an insulating flame-retardant microfiber material for automobile interior decoration, comprising the following steps: The spinning of S100 island fiber uses PA6 as the island component and LDPE as the sea component, and is spun with masterbatch to produce island fiber; The production of S200 nonwoven fabric is to use the sea island fibers prepared by S100, which are opened, carded, laid, pre-needled by a pre-needling machine and needled by a needle loom to make nonwoven fabric; S300 heat setting, heat setting the prepared nonwoven fabric; Impregnation of S400 flame-retardant polyurethane slurry to prepare insulating flame-retardant polyurethane slurry, impregnating the heat-set non-woven fabric to fully impregnate it, and then sending it into an aqueous solution of dimethylformamide for water bath curing to obtain a synthetic leather semi-finished product; S500 reduction, the semi-finished synthetic leather adopts the stripping process to extract the sea component from the island fiber; S600 post-finishing: the microfiber synthetic leather base fabric after the weight reduction in S500 is dried, immersed in a softener aqueous solution, and then dried and kneaded to obtain insulating flame-retardant microfiber leather.

[0006] Specifically, in step S100, the mass ratio of PA6 to LDPE is 45:55 to 65:35, and the amount of masterbatch added is 1.5 to 20% of the total mass of PA6, LDPE and masterbatch; the main process parameters for spinning the sea island fiber are: spinning temperature 180 to 275° C., draft ratio 3 to 12%, and fiber fineness 5 to 9 denier.

[0007] The main process parameters for making the nonwoven fabric in step S200 are: pre-needling density of 400-600 needles / cm 2 The acupuncture density is 1000 to 2300 punctures / cm 2 The number of layers is 15 to 40, the width is 3400 to 4000 mm, and the average weight is 400 to 850 g / m 2 , vehicle speed 1.5~3.0m / min.

[0008] The heat setting temperature in step S300 is 110° C. to 160° C.

[0009] The insulating flame-retardant polyurethane slurry is prepared by the following method: using at least one polyether polyurethane as a base material, then adding 1% to 20% by weight of a solvent-based wet-process insulating color paste, 10% to 40% of a phosphorus-nitrogen flame retardant, and 10% to 100% of dimethylformamide to the base material and stirring evenly to obtain a mixed slurry; then adding 0.5% to 3% by weight of a non-ionic surfactant and 0.5% to 2% by weight of a silicone surfactant to the mixed slurry and stirring evenly.

[0010] The mass concentration of the dimethylformamide aqueous solution is 15-40%.

[0011] The water bath curing temperature is 25 to 45° C., and the curing time is 10 to 50 minutes.

[0012] The stripping process specifically comprises immersing the synthetic leather semi-finished product in toluene at a temperature of 85 to 95° C. for 35 to 60 minutes to strip out the sea component, and then washing the synthetic leather semi-finished product with hot water to remove residual toluene.

[0013] The post-finishing process specifically comprises drying the reduced microfiber synthetic leather base fabric, immersing the base fabric in a softener aqueous solution with a concentration of 5 to 20% for 10 to 60 seconds, drying the base fabric, and kneading the base fabric to obtain the insulating flame-retardant microfiber leather.

[0014] The solvent-based wet-process insulating color paste is carbon black, which is prepared after surface oxidation treatment in advance.

[0015] The technical solution of the present invention has the following advantages: As a component of the capacitive sensor for hand-off detection of the steering wheel, it is used for external protection of the sensing layer. The resistance of the ultra-fiber material provided by the present invention reaches more than 1.2 megohms, meeting the detection requirements of the intelligent driving HOD, and the flame retardancy reaches the national standard A-0. DETAILED DESCRIPTION

[0016] The technical solution of the present invention will be described clearly and completely below. Obviously, the embodiments described are only some embodiments of the present invention, not all embodiments. All other embodiments derived by persons of ordinary skill in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0017] The present invention provides a method for preparing an insulating flame-retardant automotive interior microfiber material, which specifically comprises the following steps: 1. Spinning of sea-island fibers Using PA6 as the island component and LDPE as the sea component, masterbatch is used to spin either fixed-island or unfixed-island fibers. The PA6 to LDPE mass ratio is 45:55 to 65:35, and the masterbatch addition rate is 1.5 to 20% of the total weight of PA6, LDPE, and masterbatch. The main process parameters for spinning sea-island fibers are: spinning temperature of 180 to 275°C, draft ratio of 3 to 12%, and fiber fineness of 5 to 9 denier.

[0018] 2. Production of nonwoven fabrics The above-mentioned irregular island-in-the-sea fiber or fixed island-in-the-sea fiber is selected and processed into a nonwoven fabric through opening, carding, web laying, pre-puncturing with a pre-puncturing machine and needle-punching with a needle-punching machine.

[0019] The main process parameters for the production of nonwoven fabrics are: pre-needle density of 400 to 600 needles / cm 2 The acupuncture density is 1000 to 2300 punctures / cm 2 The number of layers is 15 to 40, the width is 3400 to 4000 mm, and the average weight is 400 to 850 g / m 2 , speed 1.5~3.0m / min; apparent density of nonwoven fabric is 0.2~0.35g / cm 3 .

[0020] 3. Heat setting The prepared nonwoven fabric is heat-set at a temperature of 110°C to 160°C; the apparent density of the nonwoven fabric after heat setting is ≥0.24g / cm 3 .

[0021] 4. Impregnation of flame retardant polyurethane slurry The heat-set nonwoven fabric is soaked with polyurethane slurry, phosphorus-nitrogen flame retardant, insulating color paste and non-ionic additives to make it fully impregnated, and then sent into an aqueous solution of dimethylformamide for water bath curing to obtain a synthetic leather semi-finished product.

[0022] One or more polyether polyurethanes are used as base materials, and then 1% to 20% by weight of a solvent-based wet-process insulating color paste (the carbon black used in the insulating color paste is surface-oxidized in advance and then prepared into a wet-process color paste) is added to the base materials, 10% to 40% by weight of a phosphorus-nitrogen flame retardant is added, and 10% to 100% by weight of dimethylformamide is added to the base materials to prepare a mixed slurry with a solid content of 34% to 40%; 0.5% to 3% by weight of a non-ionic surfactant and 0.5% to 2% by weight of a silicone surfactant are added to the above slurry, and the mixture is stirred evenly to obtain an insulating flame-retardant polyurethane slurry.

[0023] The impregnated nonwoven fabric is immersed in a 15-40% DMF aqueous solution and coagulated in a water bath at 25-45°C for 10-50 minutes to solidify the polyurethane and form pores. The fabric is then washed with water. Treated deionized water is used for coagulation and washing to prevent the presence of metal ions in the water from affecting the insulation properties of the material.

[0024] 5. Reduce The synthetic leather semi-finished product prepared in step 4 is subjected to a toluene stripping process to extract the sea component from the sea-island fiber, thereby obtaining ultrafine fiber synthetic leather; the synthetic leather semi-finished product is immersed in toluene at a temperature of 85 to 95° C. for 35 to 60 minutes to strip off the sea component, and then the synthetic leather semi-finished product is washed with hot water to remove residual toluene.

[0025] 6. Finishing The microfiber synthetic leather base fabric obtained in step 5 is dried, immersed in a softener aqueous solution with a concentration of 5 to 20% for 10 to 60 seconds, dried, and kneaded to obtain insulating flame-retardant microfiber leather.

[0026] The present invention is described in detail below through specific examples.

[0027] In the following examples, the masterbatch used was TDML-01 from Shanghai Likun Chemical Technology Co., Ltd.; the insulation masterbatch TDML-15 was from Anhui Jinsheng Plastics Co., Ltd.; the phosphorus-nitrogen flame retardant TDZR-01 was from Qingdao Zhanxu International Trade Co., Ltd.; the polyether polyurethane was from Xuchuan Chemical Co., Ltd.; the nonionic surfactant TMF-11 was from Yantai Fusong Environmental Protection Technology Co., Ltd.; the silicone surfactant MC-10 was from Changyi Meichun Additive Factory; and the softener (XT-2003) was from Xintai Additive Co., Ltd. in Gaomi, Shandong Province. Insulation color paste was purchased from Jiangxi Mitsukoshi New Materials Co., Ltd.

[0028] Example 1 1. Spinning of sea-island fibers Using PA6 as the island component and LDPE as the sea component, a masterbatch is used to spin either fixed-island or unfixed-island fibers. The PA6:LDPE mass ratio is 45:55, and the masterbatch addition is 20% of the total mass of PA6, LDPE, and masterbatch. The main process parameters for spinning sea-island fibers are: spinning temperature 240°C, draft ratio 8%, and fiber fineness 6.8 denier. The masterbatch used in this example is TDML-01.

[0029] 2. Production of nonwoven fabrics The above-mentioned irregular island-in-the-sea fiber or fixed island-in-the-sea fiber is selected and processed into a nonwoven fabric through opening, carding, web laying, pre-puncturing with a pre-puncturing machine and needle-punching with a needle-punching machine.

[0030] The main process parameters for the production of nonwoven fabrics are: pre-needle density of 500 needles / cm 2 The acupuncture density is 1100 punctures / cm 2 , the number of ply is 18, the width is 3700mm, and the average weight is 750g / m 2 , speed 2.3m / min; apparent density of nonwoven fabric is 0.2g / cm 3 .

[0031] 3. Heat setting The prepared nonwoven fabric was heat-set at a temperature of 130°C; the apparent density of the nonwoven fabric after heat setting was 0.27 g / cm 3 .

[0032] 4. Impregnation of flame retardant polyurethane slurry The heat-set nonwoven fabric is soaked with polyurethane slurry, phosphorus-nitrogen flame retardant, insulating color paste and non-ionic additives to make it fully impregnated, and then sent into an aqueous solution of dimethylformamide for water bath curing to obtain a synthetic leather semi-finished product.

[0033] Using one or more polyether polyurethanes (TD-09) as a base material, 20% by weight of a phosphorus-nitrogen flame retardant TDZR-01 and 40% by weight of dimethylformamide were added to prepare a mixed slurry with a solid content of 35%. 1.5% by weight of a non-ionic surfactant TMF-11 and 1% by weight of a silicone surfactant MC-10 were added to the above slurry, and the mixture was stirred evenly to obtain an insulating flame-retardant polyurethane slurry.

[0034] The impregnated nonwoven fabric was immersed in a 30% DMF aqueous solution and coagulated in a water bath at 35°C for 30 minutes to solidify the polyurethane and form pores. The fabric was then washed. Treated deionized water was used for coagulation and washing to prevent the presence of metal ions in the water from affecting the insulation properties of the material.

[0035] 5. Reduce The synthetic leather semi-finished product obtained in step 4 is subjected to a toluene stripping process to extract the sea component from the sea island fiber, thereby obtaining ultrafine fiber synthetic leather; the synthetic leather semi-finished product is immersed in toluene at a temperature of 88°C for 35 minutes to strip off the sea component, and then the synthetic leather semi-finished product is washed with hot water to remove residual toluene.

[0036] 6. Finishing The microfiber synthetic leather base fabric obtained in step 5 was dried, immersed in a 20% softener (XT-2003) aqueous solution for 60 seconds, dried, and kneaded to obtain insulating flame-retardant microfiber leather.

[0037] Table 1: Test results of product of Example 1

[0038] Example 2 1. Spinning of sea-island fibers Using PA6 as the island component and LDPE as the sea component, a masterbatch is used to spin either fixed-island or unfixed-island fibers. The PA6:LDPE mass ratio is 55:45, and the masterbatch addition is 20% of the total mass of PA6, LDPE, and masterbatch. The main process parameters for spinning sea-island fibers are: spinning temperature 240°C, draft ratio 8%, and fiber fineness 7 denier. The masterbatch used in this example is TDML-01.

[0039] 2. Production of nonwoven fabrics The above-mentioned irregular island-in-the-sea fiber or fixed island-in-the-sea fiber is selected and processed into a nonwoven fabric through opening, carding, web laying, pre-puncturing with a pre-puncturing machine and needle-punching with a needle-punching machine.

[0040] The main process parameters for the production of nonwoven fabrics are: pre-needle density of 500 needles / cm 2 The acupuncture density is 1100 punctures / cm 2 , the number of ply is 18, the width is 3700mm, and the average weight is 750g / m 2 , speed 2.3m / min; apparent density of nonwoven fabric is 0.2g / cm 3 .

[0041] 3. Heat setting The prepared nonwoven fabric was heat-set at a temperature of 130°C; the apparent density of the nonwoven fabric after heat setting was 0.27 g / cm3 .

[0042] 4. Impregnation of flame retardant polyurethane slurry The heat-set nonwoven fabric is soaked with polyurethane slurry, phosphorus-nitrogen flame retardant, insulating color paste and non-ionic additives to make it fully impregnated, and then sent into an aqueous solution of dimethylformamide for water bath curing to obtain a synthetic leather semi-finished product.

[0043] More than one polyether polyurethane (TD-09) is used as a base material, and then 1% by weight of a solvent-based wet-process insulating color paste (the carbon black used in the insulating color paste is surface-oxidized in advance and then prepared into a wet-process color paste) is added to the base material, 20% by weight of a phosphorus-nitrogen flame retardant TDZR-01 is added, and 40% by weight of the base material is added to dimethylformamide to prepare a mixed slurry with a solid content of 35%; 1.5% by weight of a non-ionic surfactant TMF-11 and 1% by weight of a silicone surfactant MC-10 based on the mass of the mixed slurry are added to the above slurry, and the mixture is stirred evenly to obtain an insulating flame-retardant polyurethane slurry.

[0044] The impregnated nonwoven fabric was immersed in a 30% DMF aqueous solution and coagulated in a water bath at 35°C for 30 minutes to solidify the polyurethane and form pores. The fabric was then washed. Treated deionized water was used for coagulation and washing to prevent the presence of metal ions in the water from affecting the insulation properties of the material.

[0045] 5. Reduce The synthetic leather semi-finished product obtained in step 4 is subjected to a toluene stripping process to extract the sea component from the sea island fiber, thereby obtaining ultrafine fiber synthetic leather; the synthetic leather semi-finished product is immersed in toluene at a temperature of 88°C for 35 minutes to strip off the sea component, and then the synthetic leather semi-finished product is washed with hot water to remove residual toluene.

[0046] 6. Finishing The microfiber synthetic leather base fabric obtained in step 5 was dried, immersed in a 20% softener (XT-2003) aqueous solution for 60 seconds, dried, and kneaded to obtain insulating flame-retardant microfiber leather.

[0047] Table 2: Test results of product of Example 2

[0048] Example 3 1. Spinning of sea-island fibers Using PA6 as the island component and LDPE as the sea component, a masterbatch is used to spin either fixed-island or unfixed-island fibers. The PA6:LDPE mass ratio is 55:45, and the masterbatch addition level is 2% of the total mass of PA6, LDPE, and masterbatch. The main process parameters for spinning sea-island fibers are: spinning temperature 230°C, draft ratio 8%, and fiber fineness 9 denier. The masterbatch used in this example is TDML-15.

[0049] 2. Production of nonwoven fabrics The above-mentioned irregular island-in-the-sea fiber or fixed island-in-the-sea fiber is selected and processed into a nonwoven fabric through opening, carding, web laying, pre-puncturing with a pre-puncturing machine and needle-punching with a needle-punching machine.

[0050] The main process parameters for the production of nonwoven fabrics are: pre-needle density of 400 needles / cm 2 The acupuncture density is 1200 punctures / cm 2 The number of layers is 20, the width is 3700mm, and the average weight is 760g / m 2 , speed 2.3m / min; apparent density of nonwoven fabric is 0.22g / cm 3 .

[0051] 3. Heat setting The prepared nonwoven fabric was heat-set at a temperature of 137°C; the apparent density of the nonwoven fabric after heat setting was 0.28 g / cm 3 .

[0052] 4. Impregnation of flame retardant polyurethane slurry The heat-set nonwoven fabric is soaked with polyurethane slurry, phosphorus-nitrogen flame retardant, insulating color paste and non-ionic additives to make it fully impregnated, and then sent into an aqueous solution of dimethylformamide for water bath curing to obtain a synthetic leather semi-finished product.

[0053] Using one or more polyether polyurethanes (TD-09) as a base material, 20% by weight of a phosphorus-nitrogen flame retardant TDZR-01 and 40% by weight of dimethylformamide were added to prepare a mixed slurry with a solid content of 35%. 1.5% by weight of a non-ionic surfactant TMF-11 and 1% by weight of a silicone surfactant MC-10 were added to the above slurry, and the mixture was stirred evenly to obtain an insulating flame-retardant polyurethane slurry.

[0054] The impregnated nonwoven fabric was immersed in a 30% DMF aqueous solution and coagulated in a water bath at 35°C for 50 minutes to solidify the polyurethane and form pores. The fabric was then washed. Treated deionized water was used for coagulation and washing to prevent the presence of metal ions in the water from affecting the insulation properties of the material.

[0055] 5. Reduce The synthetic leather semi-finished product obtained in step 4 is subjected to a toluene stripping process to extract the sea component from the sea island fiber, thereby obtaining ultrafine fiber synthetic leather; the synthetic leather semi-finished product is immersed in toluene at a temperature of 88°C for 35 minutes to strip off the sea component, and then the synthetic leather semi-finished product is washed with hot water to remove residual toluene.

[0056] 6. Finishing The microfiber synthetic leather base fabric obtained in step 5 was dried, immersed in a 20% softener (XT-2003) aqueous solution for 60 seconds, dried, and kneaded to obtain insulating flame-retardant microfiber leather.

[0057] Table 3 Example 3 Product Test Results

[0058] Example 4 1. Spinning of sea-island fibers Using PA6 as the island component and LDPE as the sea component, a masterbatch is used to spin either fixed-island or unfixed-island fibers. The PA6:LDPE mass ratio is 55:45, and the masterbatch addition level is 2% of the total mass of PA6, LDPE, and masterbatch. The main process parameters for spinning sea-island fibers are: spinning temperature 275°C, draft ratio 8%, and fiber fineness 7 denier. The masterbatch used in this example is TDML-15.

[0059] 2. Production of nonwoven fabrics The above-mentioned irregular island-in-the-sea fiber or fixed island-in-the-sea fiber is selected and processed into a nonwoven fabric through opening, carding, web laying, pre-puncturing with a pre-puncturing machine and needle-punching with a needle-punching machine.

[0060] The main process parameters for the production of nonwoven fabrics are: pre-needle density of 500 needles / cm 2 The acupuncture density is 1200 punctures / cm 2 The number of layers is 20, the width is 3700mm, and the average weight is 760g / m 2 , speed 2.3m / min; apparent density of nonwoven fabric is 0.22g / cm 3 .

[0061] 3. Heat setting The prepared nonwoven fabric was heat-set at a temperature of 137°C; the apparent density of the nonwoven fabric after heat setting was 0.28 g / cm 3 .

[0062] 4. Impregnation of flame retardant polyurethane slurry The heat-set nonwoven fabric is soaked with polyurethane slurry, phosphorus-nitrogen flame retardant, insulating color paste and non-ionic additives to make it fully impregnated, and then sent into an aqueous solution of dimethylformamide for water bath curing to obtain a synthetic leather semi-finished product.

[0063] More than one polyether polyurethane (TD-09) is used as a base material, and then 8% by weight of a solvent-based wet-process insulating paste (the carbon black used in the insulating paste is surface-oxidized in advance and then prepared into a wet-process paste) is added to the base material, 20% by weight of a phosphorus-nitrogen flame retardant TDZR-01 is added, and 40% by weight of the base material is added to dimethylformamide to prepare a mixed slurry with a solid content of 35%; 1.5% by weight of a non-ionic surfactant TMF-11 and 1% by weight of a silicone surfactant MC-10 based on the weight of the mixed slurry are added to the above slurry, and the mixture is stirred evenly to obtain an insulating flame-retardant polyurethane slurry.

[0064] The impregnated nonwoven fabric was immersed in a 30% DMF aqueous solution and coagulated in a water bath at 35°C for 30 minutes to solidify the polyurethane and form pores. The fabric was then washed. Treated deionized water was used for coagulation and washing to prevent the presence of metal ions in the water from affecting the insulation properties of the material.

[0065] 5. Reduce The synthetic leather semi-finished product obtained in step 4 is subjected to a toluene stripping process to extract the sea component from the sea island fiber, thereby obtaining ultrafine fiber synthetic leather; the synthetic leather semi-finished product is immersed in toluene at a temperature of 88°C for 35 minutes to strip off the sea component, and then the synthetic leather semi-finished product is washed with hot water to remove residual toluene.

[0066] 6. Finishing The microfiber synthetic leather base fabric obtained in step 5 was dried, immersed in a 20% softener (XT-2003) aqueous solution for 60 seconds, dried, and kneaded to obtain insulating flame-retardant microfiber leather.

[0067] Table 4 Example 4 Product Test Results

[0068] Example 5 1. Spinning of sea-island fibers Using PA6 as the island component and LDPE as the sea component, the masterbatch is used to spin the island fiber with fixed or unfixed islands. The mass ratio of PA6 to LDPE is 45:55, and the masterbatch addition amount is 8% of the total mass of PA6, LDPE and masterbatch. The main process parameters for the island fiber spinning are: spinning temperature 200℃, draft ratio 5%, and fiber fineness 6.5 denier. The masterbatch in this example is TDML-15 2. Production of nonwoven fabrics The above-mentioned irregular island-in-the-sea fiber or fixed island-in-the-sea fiber is selected and processed into a nonwoven fabric through opening, carding, web laying, pre-puncturing with a pre-puncturing machine and needle-punching with a needle-punching machine.

[0069] The main process parameters for the production of nonwoven fabrics are: pre-needle density of 400 needles / cm 2 The acupuncture density is 2300 punctures / cm 2 The number of plywood layers is 16, the width is 3400mm, and the average weight is 580g / m 2 , speed 3.0m / min; apparent density of nonwoven fabric is 0.25g / cm 3 .

[0070] 3. Heat setting The prepared nonwoven fabric was heat-set at 160°C; the apparent density of the nonwoven fabric after heat setting was 0.28 g / cm 3 .

[0071] 4. Impregnation of flame retardant polyurethane slurry The heat-set nonwoven fabric is soaked with polyurethane slurry, phosphorus-nitrogen flame retardant, insulating color paste and non-ionic additives to make it fully impregnated, and then sent into an aqueous solution of dimethylformamide for water bath curing to obtain a synthetic leather semi-finished product.

[0072] More than one polyether polyurethane TD-09 is used as a base material, and then 3% by weight of a solvent-based wet-process insulating color paste is added to the base material (the carbon black used in the insulating color paste is surface-oxidized in advance and then prepared into a wet-process color paste), 10% by weight of a phosphorus-nitrogen flame retardant TDZR-01 is added, and 30% by weight of the base material is added to dimethylformamide to prepare a mixed slurry with a solid content of 35%; 3% by weight of a non-ionic surfactant TMF-11 and 0.5% by weight of a silicone surfactant MC-10 of the mixed slurry are added to the above slurry, and the mixture is stirred evenly to obtain an insulating flame-retardant polyurethane slurry.

[0073] The impregnated nonwoven fabric is immersed in a 20% DMF aqueous solution and coagulated in a water bath at 40°C for 30 minutes to solidify the polyurethane and form pores. The fabric is then washed with water. Treated deionized water is used for coagulation and washing to prevent the presence of metal ions in the water from affecting the insulation properties of the material.

[0074] 5. Reduce The synthetic leather semi-finished product obtained in step 4 is subjected to a toluene stripping process to extract the sea component from the sea island fiber, thereby obtaining ultrafine fiber synthetic leather; the synthetic leather semi-finished product is immersed in toluene at a temperature of 85°C for 60 minutes to strip off the sea component, and then the synthetic leather semi-finished product is washed with hot water to remove residual toluene.

[0075] 6. Finishing The microfiber synthetic leather base fabric obtained in step 5 was dried, immersed in a 20% softener (XT-2003) aqueous solution for 10 seconds, dried, and kneaded to obtain insulating flame-retardant microfiber leather.

[0076] Table 5: Test results of product of Example 5

[0077] Example 6 Using PA6 as the island component and LDPE as the sea component, a masterbatch is used to spin either fixed-island or unfixed-island fibers. The PA6:LDPE mass ratio is 60:40, and the masterbatch addition rate is 8% of the total mass of PA6, LDPE, and masterbatch. The main process parameters for spinning sea-island fibers are: spinning temperature 180°C, draft ratio 8%, and fiber fineness 8 denier. The masterbatch used in this example is TDML-15.

[0078] 2. Production of nonwoven fabrics The above-mentioned irregular island-in-the-sea fiber or fixed island-in-the-sea fiber is selected and processed into a nonwoven fabric through opening, carding, web laying, pre-puncturing with a pre-puncturing machine and needle-punching with a needle-punching machine.

[0079] The main process parameters for the production of nonwoven fabrics are: pre-needle density of 490 needles / cm 2 The acupuncture density is 1500 punctures / cm 2 , the number of ply is 25, the width is 3600mm, and the average weight is 800g / m 2 , speed 2m / min; apparent density of nonwoven fabric is 0.24g / cm 3 .

[0080] 3. Heat setting The prepared nonwoven fabric is heat-set at a temperature of 140°C; the apparent density of the nonwoven fabric after heat setting is ≥0.27g / cm 3 .

[0081] 4. Impregnation of flame retardant polyurethane slurry The heat-set nonwoven fabric is soaked with polyurethane slurry, phosphorus-nitrogen flame retardant, insulating color paste and non-ionic additives to make it fully impregnated, and then sent into an aqueous solution of dimethylformamide for water bath curing to obtain a synthetic leather semi-finished product.

[0082] More than one polyether polyurethane TD-09 is used as a base material, and then 15% by weight of a solvent-based wet-process insulating paste (the carbon black used in the insulating paste is surface-oxidized in advance and then prepared into a wet-process paste) is added to the base material, 25% by weight of a phosphorus-nitrogen flame retardant TDZR-01 is added, and 30% by weight of the base material is added to dimethylformamide to prepare a mixed slurry with a solid content of 39%; 1.2% by weight of a non-ionic surfactant TMF-11 and 1.4% by weight of a silicone surfactant MC-10 based on the mass of the mixed slurry are added to the above slurry, and the mixture is stirred evenly to obtain an insulating flame-retardant polyurethane slurry.

[0083] The impregnated nonwoven fabric was immersed in a 30% DMF aqueous solution and coagulated in a water bath at 30°C for 40 minutes to solidify the polyurethane and form pores. The fabric was then washed. Treated deionized water was used for coagulation and washing to prevent the presence of metal ions in the water from affecting the insulation properties of the material.

[0084] 5. Reduce The synthetic leather semi-finished product obtained in step 4 is subjected to a toluene stripping process to extract the sea component from the sea-island fiber, thereby obtaining ultrafine fiber synthetic leather; the synthetic leather semi-finished product is immersed in toluene at a temperature of 90°C for 40 minutes to strip off the sea component, and then the synthetic leather semi-finished product is washed with hot water to remove residual toluene.

[0085] 6. Finishing The microfiber synthetic leather base fabric obtained in step 5 was dried, immersed in a 15% softener (XT-2003) aqueous solution for 30 seconds, dried, and kneaded to obtain insulating flame-retardant microfiber leather.

[0086] Table 6: Test results of product of Example 6

[0087] Example 7 1. Spinning of sea-island fibers Using PA6 as the island component and LDPE as the sea component, a masterbatch is used to spin either fixed-island or unfixed-island fibers. The PA6:LDPE mass ratio is 65:35, and the masterbatch addition is 20% of the total mass of PA6, LDPE, and masterbatch. The main process parameters for spinning sea-island fibers are: spinning temperature 270°C, draft ratio 12%, and fiber fineness 6 denier. The masterbatch used in this example is TDML-15.

[0088] 2. Production of nonwoven fabrics The above-mentioned irregular island-in-the-sea fiber or fixed island-in-the-sea fiber is selected and processed into a nonwoven fabric through opening, carding, web laying, pre-puncturing with a pre-puncturing machine and needle-punching with a needle-punching machine.

[0089] The main process parameters for the production of nonwoven fabrics are: pre-needling density is 600 needles / cm 2 The acupuncture density is 2000 punctures / cm 2 The number of ply is 40, the width is 4000mm, and the average weight is 850g / m 2 , speed 2.2m / min; apparent density of nonwoven fabric is 0.23g / cm 3 .

[0090] 3. Heat setting The prepared nonwoven fabric is heat-set at a temperature of 120°C; the apparent density of the nonwoven fabric after heat setting is ≥0.26g / cm 3 .

[0091] 4. Impregnation of flame retardant polyurethane slurry The heat-set nonwoven fabric is soaked with polyurethane slurry, phosphorus-nitrogen flame retardant, insulating color paste and non-ionic additives to make it fully impregnated, and then sent into an aqueous solution of dimethylformamide for water bath curing to obtain a synthetic leather semi-finished product.

[0092] More than one polyether polyurethane TD-09 is used as a base material, and then 20% by weight of a solvent-based wet-process insulating color paste (the carbon black used in the insulating color paste is surface-oxidized in advance and then prepared into a wet-process color paste) is added to the base material, 40% by weight of a phosphorus-nitrogen flame retardant TDZR-01 is added, and 40% by weight of dimethylformamide is added to the base material to prepare a mixed slurry with a solid content of 40%; 2.3% by weight of a non-ionic surfactant TMF-11 and 1% by weight of a silicone surfactant MC-10 based on the mass of the mixed slurry are added to the above slurry, and the mixture is stirred evenly to obtain an insulating flame-retardant polyurethane slurry.

[0093] The impregnated nonwoven fabric is immersed in a 40% DMF aqueous solution and coagulated in a water bath at 45°C for 40 minutes to solidify the polyurethane and form pores. The fabric is then washed. Treated deionized water is used for coagulation and washing to prevent the presence of metal ions in the water from affecting the insulation properties of the material.

[0094] 5. Reduce The synthetic leather semi-finished product obtained in step 4 is subjected to a toluene stripping process to extract the sea component from the sea island fiber, thereby obtaining ultrafine fiber synthetic leather; the synthetic leather semi-finished product is immersed in toluene at a temperature of 92°C for 40 minutes to strip off the sea component, and then the synthetic leather semi-finished product is washed with hot water to remove residual toluene.

[0095] 6. Finishing The microfiber synthetic leather base fabric obtained in step 5 was dried, immersed in a 13% softener (XT-2003) aqueous solution for 40 seconds, dried, and kneaded to obtain insulating flame-retardant microfiber leather.

[0096] Table 7 Example 7 Product Test Results

[0097] Example 8 1. Spinning of sea-island fibers Using PA6 as the island component and LDPE as the sea component, a masterbatch is used to spin either fixed-island or unfixed-island fibers. The PA6:LDPE mass ratio is 50:50, and the masterbatch addition level is 1.5% of the total mass of PA6, LDPE, and masterbatch. The main process parameters for spinning sea-island fibers are: spinning temperature 180°C, draft ratio 3%, and fiber fineness 5 denier. The masterbatch used in this example is TDML-15.

[0098] 2. Production of nonwoven fabrics The above-mentioned irregular island-in-the-sea fiber or fixed island-in-the-sea fiber is selected and processed into a nonwoven fabric through opening, carding, web laying, pre-puncturing with a pre-puncturing machine and needle-punching with a needle-punching machine.

[0099] The main process parameters for the production of nonwoven fabrics are: pre-needle density of 400 needles / cm 2 The acupuncture density is 1000 punctures / cm 2 , the number of ply is 15, the width is 3400mm, and the average weight is 400g / m 2 , speed 1.5m / min; apparent density of nonwoven fabric is 0.2g / cm 3 .

[0100] 3. Heat setting The prepared nonwoven fabric is heat-set at a temperature of 110°C-160°C; the apparent density of the nonwoven fabric after heat setting is ≥0.25g / cm 3 .

[0101] 4. Impregnation of flame retardant polyurethane slurry The heat-set nonwoven fabric is soaked with polyurethane slurry, phosphorus-nitrogen flame retardant, insulating color paste and non-ionic additives to make it fully impregnated, and then sent into an aqueous solution of dimethylformamide for water bath curing to obtain a synthetic leather semi-finished product.

[0102] More than one polyether polyurethane TD-09 is used as a base material, and then 20% by weight of a solvent-based wet-process insulating color paste (the carbon black used in the insulating color paste is surface-oxidized in advance and then prepared into a wet-process color paste) is added to the base material, 40% by weight of a phosphorus-nitrogen flame retardant TDZR-01 is added, and 70% by weight of the base material is added to dimethylformamide to prepare a mixed slurry with a solid content of 34%; 0.5% by weight of a non-ionic surfactant TMF-11 and 2% by weight of a silicone surfactant MC-10 based on the mass of the mixed slurry are added to the above slurry, and the mixture is stirred evenly to obtain an insulating flame-retardant polyurethane slurry.

[0103] The impregnated nonwoven fabric was immersed in a 20% DMF aqueous solution and coagulated in a water bath at 25°C for 15 minutes to solidify the polyurethane and form pores. The fabric was then washed. Treated deionized water was used for coagulation and washing to prevent the presence of metal ions in the water from affecting the insulation properties of the material.

[0104] 5. Reduce The synthetic leather semi-finished product obtained in step 4 is subjected to a toluene stripping process to extract the sea component from the sea island fiber, thereby obtaining ultrafine fiber synthetic leather; the synthetic leather semi-finished product is immersed in toluene at a temperature of 85°C for 40 minutes to strip off the sea component, and then the synthetic leather semi-finished product is washed with hot water to remove residual toluene.

[0105] 6. Finishing The microfiber synthetic leather base fabric obtained in step 5 was dried, immersed in a 5% softener water (XT-2003) solution for 60 seconds, dried, and kneaded to obtain insulating flame-retardant microfiber leather.

[0106] Table 8 Example 8 Product Test Results

[0107] The above examples show that using either insulating fiber or insulating color paste alone can improve the product's resistance, but the effect is not satisfactory. Using a combination of insulating fiber and insulating color paste can significantly improve the product's resistance, reaching over 1.2 megohms, meeting automotive requirements. Furthermore, high-concentration DMF impregnation also helps improve resistance. A low needling density can lead to weaker fiber entanglements, resulting in slightly less uniform insulation. A low number of ply layup layers and a low needling density can also affect the product's mechanical properties.

[0108] Obviously, the above embodiments are merely examples for clarity of explanation and are not intended to limit the implementation methods. Those skilled in the art will appreciate that other variations or modifications can be made based on the above description. It is not necessary and impossible to enumerate all implementation methods here. Obvious variations or modifications arising therefrom remain within the scope of protection of the present invention.

Claims

1. A method for preparing an insulating flame-retardant microfiber material for automobile interior decoration, characterized in that: The following steps are involved: The spinning of S100 island fiber uses PA6 as the island component and LDPE as the sea component, and is spun with masterbatch to produce island fiber; The production of S200 nonwoven fabric is to use the sea island fibers prepared by S100, which are opened, carded, laid, pre-needled by a pre-needling machine and needled by a needle loom to make nonwoven fabric; S300 heat setting, heat setting the prepared nonwoven fabric; Impregnation of S400 flame-retardant polyurethane slurry to prepare insulating flame-retardant polyurethane slurry, impregnating the heat-set non-woven fabric to fully impregnate it, and then sending it into an aqueous solution of dimethylformamide for water bath curing to obtain a synthetic leather semi-finished product; S500 reduction, the semi-finished synthetic leather adopts the stripping process to extract the sea component from the island fiber; S600 post-finishing: the microfiber synthetic leather base fabric after the weight reduction in S500 is dried, immersed in a softener aqueous solution, and then dried and kneaded to obtain insulating flame-retardant microfiber leather.

2. The method for preparing the insulating flame-retardant automotive interior microfiber material according to claim 1, characterized in that: Specifically, in step S100, the mass ratio of PA6 to LDPE is 45:55 to 65:35, and the amount of masterbatch added is 1.5 to 20% of the total mass of PA6, LDPE and masterbatch; the main process parameters for spinning the sea island fiber are: spinning temperature 180 to 275° C., draft ratio 3 to 12%, and fiber fineness 5 to 9 denier.

3. The method for preparing the insulating flame-retardant automotive interior microfiber material according to claim 1, characterized in that: The main process parameters for making the nonwoven fabric in step S200 are: pre-needling density of 400-600 needles / cm 2 The acupuncture density is 1000 to 2300 punctures / cm 2 The number of layers is 15 to 40, the width is 3400 to 4000 mm, and the average weight is 400 to 850 g / m 2 , vehicle speed 1.5~3.0m / min.

4. The method for preparing the insulating flame-retardant automotive interior microfiber material according to claim 1, characterized in that: The heat setting temperature in step S300 is 110° C. to 160° C.

5. The method for preparing the insulating flame-retardant automotive interior microfiber material according to claim 1, characterized in that: The insulating flame-retardant polyurethane slurry is prepared by the following method: using at least one polyether polyurethane as a base material, then adding 1% to 20% by weight of a solvent-based wet-process insulating color paste, 10% to 40% of a phosphorus-nitrogen flame retardant, and 10% to 100% of dimethylformamide to the base material and stirring evenly to obtain a mixed slurry; then adding 0.5% to 3% by weight of a non-ionic surfactant and 0.5% to 2% by weight of a silicone surfactant to the mixed slurry and stirring evenly.

6. The method for preparing the insulating flame-retardant automotive interior microfiber material according to claim 1, characterized in that: The mass concentration of the dimethylformamide aqueous solution is 15-40%.

7. The method for preparing the insulating flame-retardant automotive interior microfiber material according to claim 1 or 6, characterized in that: The water bath curing temperature is 25 to 45° C., and the curing time is 10 to 50 minutes.

8. The method for preparing the insulating flame-retardant automotive interior microfiber material according to claim 1, characterized in that: The stripping process specifically comprises immersing the synthetic leather semi-finished product in toluene at a temperature of 85 to 95° C. for 35 to 60 minutes to strip out the sea component, and then washing the synthetic leather semi-finished product with hot water to remove residual toluene.

9. The method for preparing the insulating flame-retardant automotive interior microfiber material according to claim 1, characterized in that: The post-finishing process specifically comprises drying the reduced microfiber synthetic leather base fabric, immersing the base fabric in a softener aqueous solution with a concentration of 5 to 20% for 10 to 60 seconds, drying the base fabric, and kneading the base fabric to obtain the insulating flame-retardant microfiber leather.

10. The method for preparing the insulating flame-retardant automotive interior microfiber material according to claim 1, characterized in that: The solvent-based wet-process insulating color paste is carbon black, which is prepared after surface oxidation treatment in advance.

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