Manufacturing method and application of PVC flame-retardant coated fabric

Abstract

The invention provides a manufacturing method and application of PVC flame-retardant coated fabric, and belongs to the technical field of functional coated fabric. The method comprises the following steps of coating burdening, base cloth feeding, ironing roller pretreatment, front and back surface prime coating, first high-temperature drying, back surface prime coating, second high-temperature drying, front surface prime coating, third high-temperature drying, surface treatment, fourth drying, embossing, cooling, edge cutting and rolling. In the step of preparing the coating, used materials comprise the following components: PVC paste resin, a plasticizer, a heat stabilizer, a synergistic flame retardant, a bromine flame retardant, an adhesive, an auxiliary flame retardant, a mildew preventive and a dispersing agent. Through scientific optimization of the formula and reasonable improvement of the production process, the product has excellent double-standard B1-level flame retardant property, strong mechanical strength and wide environmental adaptability, and fully meets the use requirements of multiple scenes such as military tents, medical warehouses, exhibition and awnings.

Description

Technical Field

[0001] This invention belongs to the field of functional coated fabric technology, and relates to a method for manufacturing and application of PVC flame-retardant coated fabric. Background Technology

[0002] PVC coated fabric has been widely used in outdoor facilities, storage spaces, and temporary buildings due to its good flexibility, water resistance, weather resistance, and cost advantages. For example, military tents, medical warehouses, and exhibition hall sunshades have continuous and stringent requirements for the comprehensive performance of coated fabric.

[0003] However, existing PVC-coated fabrics still face many problems in practical applications: On the one hand, traditional PVC-coated fabrics have insufficient flame retardant properties, with most only reaching ordinary flame retardant levels, making it difficult to meet the needs of military, medical, and public exhibition scenarios with high fire safety requirements. In fire hazard environments, they are prone to rapid combustion and release toxic fumes, seriously threatening the lives and property of personnel. On the other hand, some PVC-coated fabrics have shortcomings in mechanical properties. The warp and weft tensile strength and tear load fail to meet high-strength usage standards, making them prone to damage and tearing in complex outdoor environments or during long-term use, affecting their service life. In addition, existing products lack adaptability to special environments. Some coated fabrics are not mildew-resistant, easily growing mold in humid environments, leading to material deterioration. They also have poor cold resistance, easily hardening and becoming brittle in low-temperature environments, limiting their promotion and application in cold regions.

[0004] With the increasing demands for material safety, mechanical properties, and environmental adaptability in related application fields, there is an urgent need to develop a PVC coated fabric that combines excellent flame retardancy, high strength mechanical properties, good mildew resistance, and cold resistance to meet the actual needs of military tents, medical warehouses, exhibition sunshades, and other scenarios, make up for the shortcomings of existing technologies, expand the application scope of PVC coated fabric, and enhance its market competitiveness. Summary of the Invention

[0005] The purpose of this invention is to address the aforementioned problems in existing technologies by proposing a method for manufacturing and applying a PVC flame-retardant coated fabric.

[0006] A method for manufacturing a PVC flame-retardant coated fabric includes the following steps: coating material preparation, base fabric feeding, pretreatment with ironing rollers, applying a base coat to both sides, first high-temperature drying, base coat on the reverse side, second high-temperature drying, base coat on the front side, third high-temperature drying, surface treatment, fourth drying, embossing, cooling, edge trimming, and winding. In the coating material preparation step, the materials used include the following components: PVC paste resin, plasticizer, heat stabilizer, synergistic flame retardant, brominated flame retardant, adhesive, auxiliary flame retardant, mildew inhibitor, and dispersant. The base fabric is a warp-knitted fabric, which is a fabric woven from polyester, nylon, vinylon, polypropylene synthetic filaments or cotton, linen, and silk blended yarns using a warp-knitting machine.

[0007] In the third high-temperature drying step, a multi-stage drying process with increasing temperature is adopted; in the surface treatment step, a heating method with increasing temperature is adopted.

[0008] The plasticizer is at least one of DINP, DOP, DOTP, and DINP.

[0009] The auxiliary flame retardant is at least one of aluminum hydroxide, zinc borate, magnesium hydroxide, and liquid phospholipid flame retardants;

[0010] The synergistic flame retardant is at least one of Sb2O3 flame retardant and molybdenum trioxide;

[0011] The brominated flame retardant is at least one of decabromodiphenyl ethane, bromotriazine, and brominated polystyrene;

[0012] The adhesive is at least one of the following types: 202, 950, 101, and 6808.

[0013] The heat stabilizer is a calcium-zinc stabilizer;

[0014] The mildew inhibitor is at least one of the following: liquid benzisothiazolinone BBIT-20, organic liquid mildew inhibitor DINP-5, liquid compound RHA-DM-3, and liquid J-508;

[0015] The dispersant is selected from one of the following: BYK-W961, BYK-207, DK061, DK062, and DK400.

[0016] In the surface treatment step, the surface treatment agent used is at least one of PVDF surface treatment agent, acrylic surface treatment agent, titanium dioxide surface treatment agent, and silver surface treatment agent. Based on 100 parts of PVC paste resin, the following additives are used: plasticizer 55-67 parts, heat stabilizer 2-5 parts, synergistic flame retardant 13-20 parts, brominated flame retardant 3-10 parts, auxiliary flame retardant 30-40 parts, adhesive 2-5 parts, mildew inhibitor 1-3 parts, and dispersant 0.2-0.5 parts.

[0017] Preferably, in the primer coating process, the following process parameters are required: the single-sided coating amount of the primer is 180-200 g / ㎡, and the machine speed is 17±1 m / min.

[0018] Preferably, in the first high-temperature drying step, the process parameters are as follows: the drying temperatures are 165±15℃, 175±10℃, and 185±10℃ respectively.

[0019] Preferably, in the reverse side of the primer coating step, the process parameters are as follows: primer coating amount is 500-550g / ㎡, roller pressure is 80-100bar, and machine speed is 17±1m / min.

[0020] Preferably, in the second high-temperature drying step, the process parameters are as follows: the drying temperatures are 180±5℃ and 185±5℃ respectively.

[0021] Preferably, in the primer coating step, the process parameters are as follows: topcoat application amount is 600-700g / ㎡, roller pressure is 75-85bar, and machine speed is 17±1m / min.

[0022] Preferably, in the third high-temperature drying step, the process parameters are as follows: a multi-stage drying oven process is adopted, and the drying temperatures are 140±5℃, 150±5℃, 160±5℃, 170±5℃, 180±5℃, 185±5℃, 195±5℃, and 200±5℃ in sequence.

[0023] Preferably, in the surface treatment step, the process parameters are as follows: one cut on each side with a 60-mesh surface, the heating temperatures are 120±5℃, 125±5℃, and 130±5℃ respectively, and the pressure of the pressure roller is 80-100 bar.

[0024] An application of a PVC flame-retardant coated fabric, in which the PVC flame-retardant coating is used in military tents, medical warehouses, exhibitions, and sunshades.

[0025] Compared with the prior art, the present invention has the following beneficial effects: 1. Excellent flame retardant performance and meets dual standards: The present invention constructs a synergistic flame retardant system by scientifically formulating flame retardants, so that the flame retardant performance of the product reaches the B1 level of GB8624-2012 standard and the B1 level of DIN4102-1-1998 standard. It can effectively inhibit the spread of combustion, reduce the release of toxic fumes, meet the use requirements of scenarios with extremely high fire safety requirements such as military tents and medical warehouses, and significantly improve the safety during use.

[0026] 2. Strong mechanical properties and long service life: Utilizing a multi-coating process of "ironing roller pretreatment + base coating on both sides + second coating (reverse side) + third coating (front side)," combined with appropriate base fabric selection and adhesive addition, the bonding strength between the coating and the base fabric is significantly improved. The product boasts a warp tensile strength ≥2000N / 5cm, a weft tensile strength ≥2000N / 5cm, a warp tear load ≥260N, and a weft tear load ≥230N, exhibiting excellent tensile and tear resistance. It can withstand the erosion of complex outdoor environments, extending its service life in exhibition facilities, sunshades, and other similar applications.

[0027] 3. Strong environmental adaptability and wide range of applications: The addition of 1-3 parts of anti-mold agent to the formula gives the product excellent anti-mold properties, preventing material deterioration caused by mold growth in humid environments; by optimizing the ratio of plasticizer and heat stabilizer, the product's cold resistance is improved, making it less prone to hardening and brittleness in low-temperature environments, suitable for regions with different climatic conditions. At the same time, the product also has waterproof and weather-resistant properties, successfully covering multiple fields such as military, medical, exhibition, and outdoor sunshade, expanding the application scenarios of PVC coated fabric.

[0028] 4. Balancing appearance and practicality: The double-sided acrylic 60-mesh surface treatment and embossing process not only enhance the surface texture of the product, but also improve its wear resistance and stain resistance, balancing aesthetics and practicality, and further enhancing the product's market competitiveness. Attached Figure Description

[0029] Figure 1 : Process flow diagram of the present invention. Detailed Implementation

[0030] The following are specific embodiments of the present invention, which are described in conjunction with the accompanying drawings. However, the present invention is not limited to these embodiments.

[0031] Product Specifications:

[0032] 1. Mesh fabric (polyester) specifications: 1000×1000 23×23

[0033] 2. Membrane material appearance, unit mass area, and thickness: White, 650±50g / ㎡ (reference standard: GB / T4669-2008), 0.52±0.05mm (reference standard: GB / T3820-1997)

[0034] 3. Tensile strength (N / 5cm): Warp ≥2000, Weft ≥2000 (Reference test standard: GB / T3923.1-2013)

[0035] 4. Tear load (N): Warp ≥260, Weft ≥230 (Reference test standard: GB / T3917.3.1-2009)

[0036] 5. Flame retardant performance: B1 (Reference test standard: GB8624-2012)

[0037] 6. Surface treatment: Double-sided acrylic 60 mesh

[0038] 7. Flame retardant performance: Passes B1 flame retardancy (refer to test standard: DIN4102-1-1998)

[0039] 8. Other performance requirements: It should be mildew-resistant and cold-resistant.

[0040] The specific method for manufacturing PVC flame-retardant coated fabric includes the following steps: coating material preparation, base fabric feeding, pretreatment with ironing rollers, primer coating on both sides, first high-temperature drying, primer coating on the reverse side (second coat), second high-temperature drying, primer coating on the front side (third coat), third high-temperature drying, surface treatment, fourth drying, embossing, cooling, edge trimming, and winding. In the coating material preparation step, the materials used include the following components: PVC paste resin (100 parts), plasticizer (DINP 54 parts), calcium zinc stabilizer (2.8 parts), Sb2O3 flame retardant (18 parts), brominated flame retardant (7 parts), liquid phospholipid flame retardant (10 parts), aluminum hydroxide (20 parts), magnesium hydroxide (5 parts), 6808 type adhesive (4 parts), mildew inhibitor J-508 (3 parts), and BYK-207 dispersant (0.3 parts).

[0041] The process parameters for the front and back sides of the primer are as follows: the vertical single-sided coating amount of the primer is 152g / ㎡, and the machine speed is 17±1m / min.

[0042] In the first high-temperature drying, the process parameters are as follows: the drying temperatures are 165±15℃, 175±10℃, and 185±10℃ respectively, and the heating fan speeds are 30rpm, 40rpm, and 45rpm respectively.

[0043] The process parameters for the reverse side of the primer are as follows: primer coating amount is 505g / ㎡, roller pressure is 90bar, and machine speed is 17±1m / min.

[0044] In the second high-temperature drying, the process parameters are as follows: the drying temperature is 180±5℃ and 185±5℃ respectively, and the heating fan speed is 45rpm and 45rpm respectively.

[0045] For the primer coating, the process parameters are as follows: topcoat application rate is 630g / ㎡, roller pressure is 80bar, and machine speed is 17±1m / min.

[0046] In the third high-temperature drying process, a multi-stage drying oven process is adopted, and the process parameters are as follows: the drying temperatures are 140±5℃, 150±5℃, 160±5℃, 170±5℃, 180±5℃, 185±5℃, 195±5℃, and 200±5℃ in sequence, and the heating fan speeds are 30rpm, 30rpm, 35rpm, 35rpm, 35rpm, 40rpm, 40rpm, and 40rpm in sequence.

[0047] In the surface treatment, a PMMA (acrylic) solution is prepared (diluted to a concentration of 40% using methyl ethyl ketone solution). The process parameters are as follows: one cut on each side of a 60-mesh acrylic surface, heating temperatures of 120±5℃, 125±5℃, and 130±5℃ respectively, and pressure roller pressure of 80 bar.

[0048] The specific embodiments described herein are merely illustrative examples illustrating the spirit of the invention. Those skilled in the art to which this invention pertains may make various modifications or additions to the described specific embodiments or substitute them with similar methods, without departing from the spirit of the invention or exceeding its defined scope. Although the invention has been detailed and described in the accompanying drawings and foregoing description, such descriptions are considered illustrative or exemplary rather than restrictive. It should be understood that changes and modifications can be made by those skilled in the art within the scope of the following claims.

Claims

1. A method for manufacturing a PVC flame-retardant coated fabric, characterized in that, Includes the following steps: The process includes coating material preparation, base fabric feeding, pretreatment with ironing rollers, applying primer to both sides, first high-temperature drying, primer to the reverse side, second high-temperature drying, primer to the front side, third high-temperature drying, surface treatment, fourth drying, embossing, cooling, edge trimming, and winding. In the coating material preparation step, the materials used include the following components: PVC paste resin, plasticizer, heat stabilizer, synergistic flame retardant, brominated flame retardant, adhesive, auxiliary flame retardant, mildew inhibitor, and dispersant. The base fabric is warp-knitted fabric, and a multi-stage drying process with increasing temperature is used in the third high-temperature drying step. The plasticizer is at least one of DINP, DOP, DOTP, and DINP. The auxiliary flame retardant is at least one of aluminum hydroxide, zinc borate, magnesium hydroxide, and liquid phospholipid flame retardants; The synergistic flame retardant is at least one of Sb2O3 flame retardant and molybdenum trioxide; The brominated flame retardant is at least one of decabromodiphenyl ethane, bromotriazine, and brominated polystyrene; The heat stabilizer is a calcium-zinc stabilizer; In the surface treatment step, the surface treatment agent used is at least one of PVDF surface treatment agent, acrylic surface treatment agent, titanium dioxide surface treatment agent, and silver surface treatment agent.

2. The method for manufacturing the PVC flame-retardant coated fabric as described in claim 1, characterized in that, Based on 100 parts of PVC paste resin, the amount of plasticizer added is 55-67 parts, the amount of heat stabilizer added is 2-5 parts, the amount of synergistic flame retardant added is 13-20 parts, the amount of brominated flame retardant added is 3-10 parts, and the amount of auxiliary flame retardant added is 30-40 parts.

3. The method for manufacturing the PVC flame-retardant coated fabric as described in claim 1, characterized in that, The process parameters for the front and back coat steps are as follows: the single-sided coating amount for vertical primer is 180-200 g / ㎡, and the machine speed is 17±1 m / min.

4. The method for manufacturing the PVC flame-retardant coated fabric as described in claim 1, characterized in that, In the first high-temperature drying step, the process parameters are required as follows: the drying temperatures are 165±15℃, 175±10℃, and 185±10℃ respectively.

5. The method for manufacturing the PVC flame-retardant coated fabric as described in claim 1, characterized in that, In the reverse step of the primer coating, the process parameters are as follows: the primer coating amount is 500-550g / ㎡, the pressure of the roller is 80-100bar, and the speed is 17±1m / min.

6. The method for manufacturing the PVC flame-retardant coated fabric as described in claim 1, characterized in that, In the second high-temperature drying step, the process parameters are required as follows: the drying temperatures are 180±5℃ and 185±5℃ respectively.

7. The method for manufacturing the PVC flame-retardant coated fabric as described in claim 1, characterized in that, In the primer coating and topcoat application steps, the process parameters are as follows: topcoat application amount is 600-700 g / ㎡, roller pressure is 75-85 bar, and machine speed is 17±1 m / min.

8. The method for manufacturing the PVC flame-retardant coated fabric as described in claim 1, characterized in that, In the third high-temperature drying step, the process parameters are as follows: the drying temperatures are 140±5℃, 150±5℃, 160±5℃, 170±5℃, 180±5℃, 185±5℃, 195±5℃, and 200±5℃ respectively.

9. The method for manufacturing the PVC flame-retardant coated fabric as described in claim 1, characterized in that, In the surface treatment step, the process parameters are required as follows: one cut on each side with a 60-mesh surface, the heating temperatures are 120±5℃, 125±5℃, and 130±5℃ respectively, and the pressure of the pressure roller is 80-100 bar.

10. An application of a PVC flame-retardant coated fabric, wherein the PVC flame-retardant coated fabric is the PVC flame-retardant coated fabric according to any one of claims 1-9, characterized in that, Flame-retardant PVC coatings are used in military tents, medical warehouses, exhibitions, and sunshades.

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