Preparation method of flame-retardant antistatic automotive interior fabric

Abstract

The invention relates to the technical field of automotive interior fabrics, and provides a preparation method of a flame-retardant antistatic automotive interior fabric, warp yarns of the fabric are polytetrafluoroethylene yarns and have excellent high-temperature-resistant and flame-retardant characteristics, weft yarns are stainless steel yarns, and a continuous conductive network is formed in the fabric due to the conductive characteristic of stainless steel, so that the flame-retardant antistatic automotive interior fabric is formed. Static charges can be quickly dissipated, the dust adsorption or electrostatic discharge risk caused by static accumulation is effectively prevented, and the use safety of the automotive trim is improved. The parameters of the polytetrafluoroethylene yarns are matched with those of the stainless steel yarns, so that the tensile strength and flexibility of the fabric are considered; according to the binding fabric structure, the tear resistance and the structural stability of the fabric are enhanced in an up-to-down binding mode, layering or deformation is avoided, the honeycomb intertexture structure has breathability and supporting performance, and the comfort of the interior fabric is improved; the thickness and the three-dimensional sense of the fabric are enhanced through the two-layer connection design, and the requirements of automobile interiors for attractiveness and touch sense are met.

Description

Technical Field

[0001] This invention relates to the field of automotive interior fabric technology, and in particular to a method for preparing a flame-retardant and antistatic automotive interior fabric. Background Technology

[0002] When a building catches fire, structurally weak points may collapse. The varying fire resistance and flame properties of building materials contribute to this collapse after ignition. Furthermore, the timing of the collapse is unpredictable, increasing the difficulty for firefighters in rescuing people. Developing flame-retardant and heat-insulating protective equipment would significantly improve safety. Among commonly used protective suits are fire-resistant suits for firefighters. To improve the functionality and wearability of these suits, enhance comfort, and reduce safety risks for firefighters during firefighting operations, research into flame-retardant fabrics is crucial.

[0003] With the rapid development of science, the effects of static electricity have caused many obstacles and accidents in people's daily lives. Static electricity in textile materials can affect processing and use, leading to dust accumulation. In addition to studying the effects of static electricity, it is also necessary to study the magnetic field effects generated around it. In today's information age, the application of static electricity technology has received considerable attention, especially the study of the characteristics of electrostatic discharge and its protective effects against the harmful effects of electromagnetic radiation. On the market, anti-radiation products are mostly used by pregnant women and certain professions.

[0004] Electromagnetic waves emitted during information transmission by broadcasting and television facilities, wireless communication facilities, and radar, as well as electromagnetic radiation generated by high-voltage power transmission and transformation facilities, electrified railways, urban rail transit, automobiles during operation, and industrial, scientific, and medical equipment applications, all pose significant risks. When these facilities and buildings catch fire, fabrics with flame-retardant and electromagnetic shielding properties become particularly important. Furthermore, automobiles generate static electricity during operation, thus requiring excellent flame-retardant and anti-static properties for automotive interior components. Summary of the Invention

[0005] In view of this, the purpose of this invention is to provide a method for preparing flame-retardant and antistatic automotive interior fabric, thereby solving the problems in the background art.

[0006] To achieve the above objectives, the present invention provides a method for preparing flame-retardant and antistatic automotive interior fabric, comprising the following steps: Step 1: Select polytetrafluoroethylene yarn as warp yarn and stainless steel yarn as weft yarn; Step two: By controlling the up and down movement of the warp yarns on the loom, the polytetrafluoroethylene yarn is divided into upper and lower layers to form a "shed", providing space for the introduction of the weft yarn; Step 3: The stainless steel yarn is introduced from one side of the fabric into the shed formed by the opening, completing the transverse passage of the weft yarn between the warp layers. Step four: Push the weft yarn introduced into the shed toward the edge of the fabric, which has already been woven, so that the weft yarn is tightly arranged and interwoven with the warp yarn to form the weft density and structure of the fabric. Step 5: Wind the woven fabric from the weft inlet onto the roll roller, while stabilizing the weft inlet position in the weft beating area to make room for subsequent weaving cycles. Step six: Release the warp yarn from the warp beam, i.e., the roller on which the warp yarn is wound, to provide a continuous supply of warp yarn for shedding and weft insertion, and to control the warp yarn tension to be stable; Step seven: Repeat steps two through six to weave the fabric.

[0007] Preferably, the polytetrafluoroethylene yarn has a density of 138.86 tex, a breaking strength of 42 N, and an elongation of 15%.

[0008] Preferably, the stainless steel yarn has a density of 90.91 tex, a breaking strength of 3 N, and an elongation of 2.5%.

[0009] Preferably, the fabric is a top-to-bottom spliced ​​fabric.

[0010] Preferably, the polytetrafluoroethylene yarn and the stainless steel yarn each account for 50%.

[0011] Preferably, step two employs a "delayed opening" process, delaying the opening time by 10°-15° of the loom spindle rotation angle to reduce the friction frequency between the PTFE yarn and the heddle wires. The heddle frame uses ceramic eyes to reduce warp scratches.

[0012] Preferably, the fabric undergoes padding-baking treatment after weaving.

[0013] Preferably, the padding solution for the padding-baking treatment is a mixture of 10%-15% phosphorus-based flame retardant and 5% organosilicon resin, and the baking temperature is 150-160℃.

[0014] The beneficial effects of this invention are as follows: The warp yarn of the fabric is made of polytetrafluoroethylene (PTFE) yarn, which has excellent high-temperature resistance and flame retardant properties. The weft yarn is made of stainless steel yarn. The conductivity of stainless steel forms a continuous conductive network in the fabric, which can quickly dissipate static charge and effectively prevent dust adsorption or electrostatic discharge risks caused by static accumulation, thus improving the safety of automotive interiors. The parameters of PTFE yarn (42N breaking strength, 15% elongation) and stainless steel yarn (3N breaking strength, 2.5% elongation) are matched, balancing the tensile strength and flexibility of the fabric. The spliced ​​fabric structure, through the "top-to-bottom" splicing method, enhances the tear resistance and structural stability of the fabric, avoiding delamination or deformation. The honeycomb interwoven structure combines breathability and support, improving the comfort of the interior fabric. The two-layer splicing design enhances the thickness and three-dimensionality of the fabric, meeting the requirements of automotive interiors for aesthetics and tactile feel. During the weaving process, the stable control of warp yarn tension in step six and the tight weft stitching in step four ensure uniform weft density and improve overall mechanical properties. The cyclical process of steps two through six—shedding, weft insertion, beat-up, winding, and warp feeding—achieves automated continuous production. Combined with stable warp tension control and fixed weft insertion position, this ensures uniform fabric density and consistent structure, reducing the defect rate. The padding-baking treatment allows flame retardants and silicone resins to fully penetrate and cure, not only improving flame retardancy and antistatic durability but also imparting certain waterproof and stain-resistant properties to the fabric, meeting the requirements of easy cleaning and aging resistance for automotive interiors. Detailed Implementation

[0015] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to specific embodiments.

[0016] It should be noted that, unless otherwise defined, the technical or scientific terms used in this invention should have the ordinary meaning understood by one of ordinary skill in the art to which this invention pertains. The terms "first," "second," and similar terms used in this invention do not indicate any order, quantity, or importance, but are merely used to distinguish different components. Terms such as "comprising" or "including" mean that the element or object preceding the word encompasses the elements or objects listed following the word and their equivalents, without excluding other elements or objects. Terms such as "connected" or "linked" are not limited to physical or mechanical connections, but can include electrical connections, whether direct or indirect. Terms such as "upper," "lower," "left," and "right" are used only to indicate relative positional relationships; when the absolute position of the described object changes, the relative positional relationship may also change accordingly. Example 1

[0017] This embodiment provides a method for preparing flame-retardant and antistatic automotive interior fabric, including the following steps: S1 uses polytetrafluoroethylene (PTFE) yarn as the warp yarn, with a density of 138.86 tex, a breaking strength of 42 N, and an elongation of 15%; and stainless steel yarn as the weft yarn, with a density of 90.91 tex, a breaking strength of 3 N, and an elongation of 2.5%. S2 controls the up-and-down movement of the warp yarns through the loom, causing the PTFE yarn to be divided into upper and lower layers to form a "shed," providing space for the introduction of the weft yarn. It adopts a "delayed shedding" process, delaying the shedding time by 10°-15° loom spindle rotation angle to reduce the friction frequency between the PTFE yarn and the heddle wires. The heddle frame uses ceramic eyes to reduce warp yarn scratches. S3, stainless steel yarn is introduced from one side of the fabric into the shed formed by the opening, completing the transverse passage of the weft yarn between the warp layers; S4, push the weft yarn introduced into the shed towards the edge of the fabric, which has already been woven, so that the weft yarn is closely arranged and interwoven with the warp yarn to form the weft density and structure of the fabric. S5, the woven fabric is wound from the weft inlet onto the roll roller, and the weft inlet position is stabilized in the weft beating area, making room for subsequent weaving cycles; S6 releases the warp yarn from the warp beam, i.e., the roller on which the warp yarn is wound, to provide a continuous supply of warp yarn for shedding and weft insertion, and to control the stability of the warp yarn tension; S7, the loop S2-S6 is woven into a jointed fabric, with polytetrafluoroethylene yarn and stainless steel yarn each accounting for 50%; S7. After the fabric is woven, it undergoes padding-baking treatment. The padding solution for padding-baking treatment is a mixture of 15% phosphorus flame retardant and 5% organosilicon resin, and the baking temperature is 160℃.

[0018] The basic properties of Example 1 and other fabrics with different weave structures are shown in the table below, where the "top-to-bottom" joint (50% stainless steel yarn) is Example 1:

[0019] .

[0020] Example 1 and other fabric structures were tested for fire resistance and flame retardancy according to the national standard GB / T5455-2014, the standard for the flammability of textiles. Afterflame time, smoldering time, and damage length were measured. The test data are shown in the table below:

[0021]

[0022] Pure polytetrafluoroethylene (PTFE) yarn melts but does not burn, nor does it continue to ignite or smolder. Stainless steel fibers are characterized by their high-temperature resistance. The material used in this experiment was pure stainless steel fiber, which does not burn, nor does it exhibit afterflame or smoldering. The damaged lengths of the warp and weft fabrics ranged from approximately 1.5 to 10.5 nm, with the warp fabric generally showing greater damage than the weft fabric because the weft yarns in this experiment were all stainless steel. The damage to the fabric was due to the melting of PTFE, while the stainless steel yarns only showed signs of burning.

[0023] In honeycomb weave fabrics, the melting of PTFE in the warp direction causes the stainless steel yarns to shrink, resulting in a shorter warp length. The PTFE in the weft direction also shrinks, but this does not affect the stainless steel yarns. In twill weave fabrics, the stainless steel yarns in the weft direction lengthen by 3mm when the PTFE melts. This is because the melting of PTFE alters the fabric's structure, causing the interlacing points to disappear, thus lengthening the stainless steel yarns. As the stainless steel yarn content in the weave increases, the fabric damage length gradually decreases. For different weave structures, the three-layer honeycomb weave and the interlacing damage length are the lowest, at 3cm.

[0024] Example 1: Antistatic performance test of fabrics with other structures: The half-life method was used: After the sample was charged to a stable state in a high-voltage electrostatic field, the high-voltage power supply was disconnected, and the voltage was allowed to decay naturally through contact with a grounded metal platform. The time required for the voltage to decay to half of the initial voltage was measured, in seconds. Experimental instrument: YG(B)342E fabric inductive electrostatic meter. The test data are shown in the table below:

[0025] Analysis of the chart data reveals that pure polytetrafluoroethylene (PTFE) exhibits the worst antistatic performance, with a static voltage of 1315V. In contrast, all other fabrics containing stainless steel yarns show a static voltage of 0V, indicating better antistatic properties. As shown in the chart, the shorter the half-life of the fabric increases with the increase in stainless steel yarn content, the better its antistatic properties. Pure stainless steel plain weave fabric demonstrates the best antistatic performance, with a half-life of 0.32s. Among interwoven fabrics, the three-layer honeycomb weave exhibits the worst antistatic performance at 1.83s, likely due to its lower stainless steel fiber content.

[0026] Air permeability tests were conducted on the fabrics of Example 1 and the remaining fabric structures:

[0027] (1) Principle: Under a specified pressure difference, the air flow rate passing vertically through the sample per unit time is measured, and the air permeability of the fabric is calculated. Theoretically speaking, when the selected nozzle number is fixed, the greater the pressure, the greater the flow rate passing through the sample per unit area per second; if the nozzle numbers are different, when the pressure is the same, the larger the nozzle number, the greater the air flow rate per unit time. Different fabrics should select different nozzle numbers according to their characteristics

[23] .

[0028] (2) Specimen: The test area is 20 cm² 2 Large sample blocks can be used directly for testing, measuring five different sample positions.

[0029] (3) Test instrument: YG46E-41 fabric air permeability tester (Ningbo Textile Instrument Factory).

[0030] (4) Test procedure: Check the zero point of the inclined tube manometer and the zero point of the flow differential pressure gauge. Select the constant pressure state, generally select a pressure of 100 Pa, select the flow orifice size as nozzle number 20, place the test sample, and ensure that the test part of the sample is smooth and flat and has a certain distance from the edge of the cloth. Adjust the pressure head height, pull down the pressure handle, tighten the sample, press the start button, and repeat this step at least 5 times.

[0031] The breathability test data are shown in the table below:

[0032] The data in the table shows that the overall air permeability of pure stainless steel fabrics is lower than that of PTFE / stainless steel interwoven fabrics. This is because PTFE has a smooth surface and a low coefficient of friction, making it difficult to tighten the weft yarns. Stainless steel yarns, on the other hand, have a high coefficient of friction, which facilitates tight bonding of warp and weft yarns during weaving, resulting in a tighter fabric. The air permeability of fabrics with different weave structures is as follows: honeycomb > satin > twill > plain weave > knotted > three-layer knotted honeycomb. This is because plain weave fabrics have the most interlacing of warp and weft yarns, resulting in smaller gaps between yarns and lower air permeability. Multi-layered fabrics have a higher warp and weft density than single-layered fabrics, hence their lower air permeability. As the fabric structure and density change, the air permeability increases with the increase in float length. In PTFE / stainless steel interwoven fabrics, the air permeability decreases with increasing stainless steel fiber content. This is because stainless steel yarns have a high coefficient of friction, which facilitates tight weft yarn bonding. When the warp density is constant, increasing the weft density increases the fabric tightness, decreases the porosity, and thus reduces air permeability. There is an inverse relationship between the number of interlacing layers and the yarn spacing. Smaller spacing results in poorer air permeability, requiring more interlacing layers; conversely, larger spacing results in better air permeability, requiring fewer interlacing layers. Due to the unique nature of honeycomb weave, it has the largest space between yarns, resulting in excellent air permeability. Plain weave fabrics, on the other hand, have the highest yarn density and tightest weave, making them the least breathable among single-layer fabrics.

[0033] Stiffness tests were conducted on the fabrics of Example 1 and the remaining fabric structures:

[0034] (1) Principle: A sample of a certain size is extended horizontally little by little. Under its own weight, it bends to a certain degree. The length of the extension is measured. The longer the extension, the better the stiffness, and vice versa. This is used as the test index for the stiffness of the fabric.

[0035] (2) Test instrument: FY207 stiffness tester (3) Experimental steps: Prepare the sample. The sample size is 25cm × 2.5cm. At least 6 pieces of the sample need to be cut, divided into warp and weft directions, with 3 pieces cut for each sample. Place the sample under standard atmospheric conditions for humidification. Turn on the instrument switch and set the experimental parameters according to the sample requirements. The main settings are the fabric weight per square meter and the speed. Then place the sample on the worktable, aligning the front end of the sample with the platform on the same horizontal plane. Then press the flip plate to hold the sample down. Press the work button. The sample moves forward at a constant speed under the action of the flip plate until the front end of the sample tilts downward to the inclined plane detector. The instrument stops testing and begins to return. Record the sample data at this time. Repeat this step to obtain the experimental data as shown in the table below. The extension length is twice the bending length. The formula for calculating the bending stiffness B is as follows: B = 9.18 × 10-8 WLB3. In the formula: B: Bending stiffness (cN·cm) 2 / cm); LB: Bending length, mm; W: Mass per unit area of ​​the sample, g / cm³ 2 ; The stiffness test data is shown in the table below:

[0036] As the stainless steel fiber content increases, the stiffness of the PTFE-stainless steel interwoven fabric gradually increases in both the warp and weft directions, with the warp stiffness being significantly greater than the weft stiffness. This is because most of the warp yarn in the interwoven fabric is PTFE, and PTFE yarn has a high yarn count, is relatively stable, and its shape is not easily changed. Furthermore, the high coefficient of friction of stainless steel increases the fabric tightness during interweaving. Therefore, increasing the stainless steel yarn content also reduces the porosity of the PTFE warp yarns, resulting in a denser weave. For different weave structures, the stiffness of three-layer fabrics is > double-layer fabrics > single-layer fabrics. However, for the special honeycomb weave structure, the stiffness is comparable to that of three-layer fabrics. The radial stiffness is highest in honeycomb and three-layer fabrics, with an average extension length greater than 90 mm. Plain weave is next, followed by twill, knotted, and satin weaves, with satin being the lowest. In this experiment, the fabric samples with a warp extension length greater than 70 mm were stiffer and had poor wearability. In the weft direction, the stiffness variation of other structures is consistent with that in the warp direction. However, for honeycomb structures, the smooth surface of the polytetrafluoroethylene in the fabric makes the fabric less dense during weaving, and the bending stiffness in the weft direction is not as good as that in the warp direction.

[0037] The test data above shows that: 1) With the increase of stainless steel fiber content, the stiffness of the PTFE and stainless steel interwoven fabric gradually increases in both the warp and weft directions, with the warp stiffness being significantly greater than the weft stiffness. For different weave structures, the stiffness of three-layer fabric > two-layer fabric > single-layer fabric, but for the special honeycomb weave structure, the stiffness is comparable to that of three-layer fabric. In the radial direction, the stiffness of honeycomb and three-layer fabrics is the greatest, with an average extension length greater than 90 mm, followed by plain weave, then twill, knotted, and satin weaves, decreasing in that order, with satin being the lowest. In this experiment, the fabric samples with a warp extension length greater than 70 mm were stiffer and had poor wearability. In the weft direction, the stiffness variation of other weaves is consistent with that of the warp direction, but for the honeycomb weave, due to the smooth surface of the PTFE in the fabric, the fabric is not tightly woven, and the weft bending stiffness is not as good as that of the warp direction.

[0038] 2) In fabrics where polytetrafluoroethylene (PTFE) is not interwoven with stainless steel, the air permeability of the fabric decreases as the stainless steel fiber content increases. This is because stainless steel yarns have a high coefficient of friction, which facilitates tightening the weft yarns.

[0039] 3) Due to the excellent flame-retardant properties of stainless steel yarn, interwoven fabrics with varying stainless steel fiber content all exhibit excellent flame-retardant performance. Interwoven fabrics containing stainless steel yarn leave a skeleton after burning, therefore the presence of stainless steel fibers is beneficial to the flame-retardant effect of the interwoven fabric.

[0040] 4) The fabric weave and stainless steel fiber content both have a certain impact on the electromagnetic radiation shielding performance of the fabric. Three-layer honeycomb weave offers the best shielding effectiveness, while fabrics with a higher stainless steel fiber content provide even better shielding. To ensure wearing comfort, fabrics with a lower stainless steel fiber content should be selected while still achieving antistatic effects.

[0041] The results showed that the stainless steel fiber content and weave structure affected the flame retardant, antistatic, and electromagnetic shielding properties of the fabric. Higher stainless steel fiber content resulted in better antistatic, flame retardant, and electromagnetic shielding properties, but poorer fabric softness and breathability. Among these, multi-layered weaves exhibited better flame retardant, antistatic, and electromagnetic shielding properties than single-layered fabrics, while three-layered honeycomb weaves showed the best flame retardant and electromagnetic shielding properties. Analysis of the results indicated that the optimal parameters for functionality and wearability were a weave with a stainless steel fiber content of 50%.

[0042] Those skilled in the art should understand that the discussion of any of the above embodiments is merely exemplary and is not intended to imply that the scope of the invention is limited to these examples; within the framework of the invention, the technical features of the above embodiments or different embodiments can also be combined, the steps can be implemented in any order, and many other variations of different aspects of the invention as described above exist, which are not provided in detail for the sake of brevity. Any omissions, modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the invention should be included within the scope of protection of the invention.

Claims

1. A process for the preparation of a flame retardant antistatic automotive interior fabric characterized in that, It comprises the following steps: Step one, select polytetrafluoroethylene yarn as warp, stainless steel yarn as weft; Step two, through the loom control warp up and down movement, so that polytetrafluoroethylene yarn into two layers of upper and lower form "shed", for weft introduction to provide space; Step three, stainless steel yarn as from one side of the fabric into the opening formed in the shed, complete the weft in the warp layer horizontal penetration; Step four, the weft introduced into the shed to the weaving edge of the fabric, so that the weft close arrangement and interweave with the warp fixed, forming the weft density and structure of the fabric; Step five, the fabric has been woven from the weaving edge of the fabric winding to the cloth roll, while the weaving edge position stable in beating-up area, for subsequent weaving cycle to free up space; Step six, from the warp beam, that is, the release of warp yarn winding drum, for the opening, weft to provide continuous warp supply, and control the warp tension stability; Step seven, the cycle of step two-step six weaving fabric.

2. A process for preparing a flame retardant antistatic automotive interior fabric as claimed in claim 1, wherein, The density of the polytetrafluoroethylene yarn is 138.86 tex, the breaking strength is 42N, and the elongation is 15%.

3. A process for preparing a flame retardant antistatic automotive interior fabric as claimed in claim 2, wherein, The density of the stainless steel yarn is 90.91 tex, the breaking strength is 3N, and the elongation is 2.5%.

4. A process for preparing a flame retardant antistatic automotive interior fabric as claimed in claim 3, wherein, The fabric is an over-under stitching fabric.

5. A process for preparing a flame retardant antistatic automotive interior fabric as claimed in claim 4, wherein, The polytetrafluoroethylene yarn and stainless steel yarn each account for 50%.

6. A process for preparing a flame retardant antistatic automotive interior fabric as claimed in claim 1, wherein, The step two adopts "late shedding" process, the opening time delay 10°-15° loom spindle angle, reduce the friction frequency of PTFE yarn and heald, the heald frame adopts ceramic eye, reduce the warp scratch.

7. A process for preparing a flame retardant antistatic automotive interior fabric as claimed in claim 1, wherein, The fabric after weaving is subjected to dip-cure treatment.

8. A process for preparing a flame retardant antistatic automotive interior fabric as claimed in claim 7, wherein, The dip-cure treatment is a mixture of 10%-15% phosphorus flame retardant and 5% silicone resin, and the curing temperature is 150-160℃.

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