A method of making a high flame resistant and formable felt

Abstract

This invention relates to a method for manufacturing a highly flame-retardant and formable felt, comprising the following steps: Step S1: Weighing flame-retardant fiber material and pre-oxidized fiber material and feeding them in a proportional manner; Step S2: Tearing and mixing the flame-retardant fiber material and pre-oxidized fiber material until a mixture is formed; Step S3: Combing the mixture until a first fiber web composed of multiple fibers with the same orientation is formed; Step S4: Laying the first fiber web on a conveyor until a second fiber web is formed; Step S5: Punching the second fiber web until a first felt material is formed; Step S6: Covering the surface of the first felt material with an isolation film until a second felt material is formed; Step S7: Heating the second felt material until the low-melting-point fibers within the second felt material melt to form a third felt material; Step S8: Pressing and molding the third felt material. This invention provides a method for manufacturing a highly flame-retardant and formable felt, which can reduce the weight of flame-retardant parts under high flame-retardant requirements.

Description

Technical Field

[0001] This invention relates to the field of felt manufacturing technology, and in particular to a method for manufacturing highly flame-retardant and formable felt. Background Technology

[0002] Currently, some vehicle parts require the use of flame-retardant materials, such as suspended trunk mats, seat back panels, or headliners, which require flame-retardant felt to prevent the fire from spreading rapidly in the event of an accident. Because the risk of combustion in gasoline-powered vehicles is relatively low, the flame-retardant requirements for the felt are lower. However, the risk of combustion in electric vehicles is relatively higher than in gasoline-powered vehicles, therefore, the flame-retardant felt for electric vehicles needs to meet higher requirements. To achieve higher flame-retardant requirements, the current approach is to increase the amount of flame-retardant material used, such as thickening the parts. However, this method results in heavier flame-retardant parts in the vehicle. Summary of the Invention

[0003] Therefore, the technical problem to be solved by the present invention is to provide a method for manufacturing highly flame-retardant and formable felt, which can reduce the weight of flame-retardant parts under high flame-retardant requirements.

[0004] To solve the above-mentioned technical problems, the present invention provides a method for manufacturing a highly flame-retardant and formable felt, comprising the following steps: Step S1: Weighing the flame-retardant fiber material and the pre-oxidized fiber material and feeding them in proportion; Step S2: Tearing and mixing the flame-retardant fiber material and the pre-oxidized fiber material until a mixture is formed; Step S3: Combing the mixture until a first fiber web composed of multiple fibers with the same orientation is formed; Step S4: Laying the first fiber web on a conveyor until a second fiber web is formed; Step S5: Punching the second fiber web until a first felt material is formed; Step S6: Covering the surface of the first felt material with an isolation film until a second felt material is formed; Step S7: Heating the second felt material until the low-melting-point fibers in the second felt material melt to form a third felt material; Step S8: Pressing and molding the third felt material.

[0005] In one embodiment of the present invention, in step S1, the flame-retardant fiber material is a low-melting-point flame-retardant fiber material, the proportion of flame-retardant fiber material is 30%-50%, and the proportion of pre-oxidized fiber material is 50%-70%.

[0006] In one embodiment of the present invention, in step S2, the flame-retardant fiber material and the pre-oxidized fiber material are shredded into flocculent form and mixed.

[0007] In one embodiment of the present invention, in step S5, a second fiber network is pierced by a barbed needle with a barb hook.

[0008] In one embodiment of the present invention, in step S6, the separator is a nylon composite membrane.

[0009] In one embodiment of the present invention, in step S6, a film-applying assembly is set to apply a release film to the first felt material. The film-applying assembly includes a first feeding roller, a second feeding roller, a driven roller, and a heating roller. The first feeding roller is used to convey the first felt material, and the second feeding roller is used to convey the release film. The release film is wound around the heating roller, and the first felt material passes between the driven roller and the heating roller and is applied to the release film.

[0010] In one embodiment of the present invention, in step S7, a heating assembly is set to heat the second felt material. The heating assembly includes a first heating plate and a second heating plate, and the second felt material is clamped between the first heating plate and the second heating plate.

[0011] In one embodiment of the present invention, the heating temperatures of the first heating plate and the second heating plate can be controlled independently.

[0012] In one embodiment of the present invention, in step S8, a molding assembly is set to press and mold the third felt material. The molding assembly includes a driving mechanism, a base, a first pressure plate and a second pressure plate. The first pressure plate is connected to the execution end of the driving mechanism, the second pressure plate is connected to the base, and the third felt material is clamped between the first pressure plate and the second pressure plate.

[0013] In one embodiment of the present invention, both the first pressure plate and the second pressure plate are capable of cooling.

[0014] The technical solution of the present invention has the following advantages compared with the prior art:

[0015] The present invention discloses a method for manufacturing a highly flame-retardant and formable felt. In step S5, the fiber web is punctured, causing the fibers in the loose fiber layer to entangle with each other, thereby improving the strength of the flame-retardant part. In step S7, the heating of the second felt material melts the low-melting-point fibers in the second felt material, allowing the fibers inside the flame-retardant part to bond together, further improving the strength of the flame-retardant part. By improving the strength of the flame-retardant part and by using a mixture of flame-retardant fiber material and pre-oxidized fiber material, high flame-retardant requirements can be maintained and the weight of the flame-retardant part can be reduced while reducing the amount of fiber material used. Attached Figure Description

[0016] To make the content of this invention easier to understand, the invention will be further described in detail below with reference to specific embodiments and accompanying drawings.

[0017] Figure 1 This is a flowchart of a method for manufacturing a highly flame-retardant and formable felt according to the present invention;

[0018] Figure 2 This is a schematic diagram of the internal structure of the film application assembly;

[0019] Figure 3 This is a schematic diagram of the internal structure of the heating component;

[0020] Figure 4 This is a structural schematic diagram of the molded component.

[0021] Explanation of reference numerals in the accompanying drawings: 1. First feeding roller; 2. First heating plate; 3. Drive mechanism; 11. Second feeding roller; 12. First felt material; 13. Separating membrane; 14. Driven roller; 15. Heating roller; 16. Second felt material; 21. Second heating plate; 31. Base; 32. First pressure plate; 33. Second pressure plate; 34. Third felt material. Detailed Implementation

[0022] The present invention will be further described below with reference to the accompanying drawings and specific embodiments, so that those skilled in the art can better understand and implement the present invention. However, the embodiments described are not intended to limit the present invention.

[0023] Reference Figure 1 As shown, a method for manufacturing a highly flame-retardant and formable felt according to the present invention includes the following steps: Step S1: Weighing the flame-retardant fiber material and the pre-oxidized fiber material and feeding them in proportion; Step S2: Tearing and mixing the flame-retardant fiber material and the pre-oxidized fiber material until a mixture is formed; Step S3: Combing the mixture until a first fiber web composed of multiple fibers with the same orientation is formed; Step S4: Laying the first fiber web on a conveyor until a second fiber web is formed; Step S5: Punching the second fiber web until a first felt 12 is formed; Step S6: Covering the surface of the first felt 12 with a release film 13 until a second felt 16 is formed; Step S7: Heating the second felt 16 until the low-melting-point fibers in the second felt 16 melt to form a third felt 34; Step S8: Pressing the third felt 34 into shape.

[0024] This embodiment discloses a method for manufacturing a highly flame-retardant and formable felt. In step S5, the fiber web is punctured, causing the fibers in the loose fiber layer to entangle with each other, thereby improving the strength of the flame-retardant part. In step S7, the second felt 16 is heated, causing the low-melting-point fibers in the second felt 16 to melt, allowing the fibers inside the flame-retardant part to bond together, further improving the strength of the flame-retardant part. By improving the strength of the flame-retardant part and using a mixture of flame-retardant fiber material and pre-oxidized fiber material, high flame-retardant requirements can be maintained and the weight of the flame-retardant part can be reduced while reducing the amount of fiber material used.

[0025] Step S1 involves weighing the flame-retardant fiber material and the pre-oxidized fiber material and then feeding them in proportion. Specifically, the flame-retardant fiber material is a low-melting-point flame-retardant fiber material, wherein the proportion of flame-retardant fiber material is 30%-50%, and the proportion of pre-oxidized fiber material is 50%-70%. The weighing and proportional distribution of the flame-retardant fiber material and the pre-oxidized fiber material can be completed by an automatic weighing and unpacking machine.

[0026] Step S2 involves shredding and mixing the flame-retardant fiber material and pre-oxidized fiber material until a mixture is formed. Specifically, the flame-retardant fiber material and pre-oxidized fiber material are shredded into flocculent form and mixed. This mixing process can be completed through a mixing bin, which is equipped with a rotating mixing roller. The mixing roller has multiple first protrusions with pointed ends. Through the rotation of the mixing roller, the flame-retardant fiber material and pre-oxidized fiber material in the bin can be broken up and shredded into flocculent form. As the fiber material descends, it is subjected to the action of rotating air force, thereby fully mixing the fiber material and breaking up the whole fiber material into multiple small fiber clumps. In another embodiment, to further improve the flame-retardant requirements of the flame-retardant parts, a flame retardant can be added when mixing the flame-retardant fiber material and pre-oxidized fiber material.

[0027] Step S3 involves carding the mixture until a first fiber web is formed, consisting of multiple fibers with the same orientation. Specifically, the mixture can be carded using a random carding machine. The random carding machine contains a rotating first carding roller and a second carding roller. Multiple second carding rollers are arranged circumferentially around the first carding roller, and the diameter of the second carding roller is smaller than that of the first carding roller. The first and second carding rollers rotate in opposite directions. The first carding roller has multiple second protrusions tangentially arranged along the rotation direction, with pointed ends. The second carding roller has multiple third protrusions arranged along the rotation direction, with pointed ends, thus ensuring that the second and third protrusions face opposite directions. The gap between the first and second carding rollers can be adjusted according to the fiber thickness. When the fiber is coarser, the gap is increased; when the fiber is finer, the gap is decreased. To further improve the carding effect and efficiency of the mixture, a third carding roller can be installed inside the random carding machine. The third carding roller is located to one side of the second carding roller, and its diameter is smaller than that of the second carding roller. The structure and rotation direction of the third carding roller are the same as those of the second carding roller. Through the rotation of the carding roller, the mixture gradually forms a first fiber web composed of multiple fibers with the same orientation.

[0028] Step S4 involves laying the first fiber web onto the conveyor until a second fiber web is formed. Specifically, the first fiber web is laid into the second fiber web using a web-laying machine. The web-laying machine has multiple conveyor components at different heights. The first fiber web is conveyed vertically and reciprocally by these multiple conveyor components, thereby achieving cross-laying and ultimately forming a second fiber web composed of multiple layers of stacked first fiber webs.

[0029] Step S5 involves piercing the second fiber web until the first felt 12 is formed. Specifically, the second fiber web is pierced using a needle punching machine. The needle punching machine contains multiple movable needles with barbs. The barbs are angled along the direction of needle penetration towards the second fiber web. Through the piercing of the second fiber web, the fibers within the loose fiber layer become entangled and form a wedge-shaped structure, thereby improving the strength of the flame-retardant part. Because the pre-oxidized fiber material has fine fibers, the specifications of the needles need to be adjusted according to the diameter of the fiber material.

[0030] Step S6 involves attaching a release film 13 to the surface of the first felt 12 until a second felt 16 is formed. Specifically, the release film 13 is a nylon composite film, specifically a PE / PA film. The release film 13 comprises two layers: a first film material and a second film material, wherein the first film material has a higher melting point and the second film material has a lower melting point. (Refer to...) Figure 2 As shown, a film-applying assembly is provided to apply a release film 13 to a first felt material 12. The film-applying assembly includes a first feeding roller 1, a second feeding roller 11, a driven roller 14, and a heating roller 15. The first feeding roller 1 is used to transport the first felt material 12, and the second feeding roller 11 is used to transport the release film 13. The release film 13 is wound around the heating roller 15, and the first film material is bonded to the heating roller 15. The heating temperature of the heating roller 15 is 195℃-205℃. The first felt material 12 passes between the driven roller 14 and the heating roller 15 and is bonded to the release film 13. The driven roller 14 and the heating roller 15 compress the release film 13 and the first felt material 12, while the second film material is bonded to the first felt material 12. The heating of the release film 13 by the heating roller 15 melts the second film material, while the first film material remains in its original shape, thereby bonding the release film 13 to the first felt material 12.

[0031] Step S7 involves heating the second felt 16 until the low-melting-point fibers within it melt, forming the third felt 34. (Refer to...) Figure 3As shown, a heating assembly is provided to heat the second felt 16. This heating assembly can be considered a contact heating furnace and includes a first heating plate 2 and a second heating plate 21. The first heating plate 2 is located above the second heating plate 21, and the second felt 16 is sandwiched between the first heating plate 2 and the second heating plate 21. Heating the second felt 16 melts the low-melting-point fibers within it, allowing the fibers inside the flame-retardant part to bond together, further improving the strength of the flame-retardant part. The heating temperatures of the first heating plate 2 and the second heating plate 21 can be controlled independently. Specifically, each of the first heating plate 2 and the second heating plate 21 has an independent heating unit, which is connected to a controller that controls the heating temperature of the heating unit. The first heating plate 2 abuts against one side of the release film on the second felt 16, and the second heating plate 21 abuts against the other side of the second felt 16. The heating temperature of the first heating plate 2 is 195℃-205℃, and the heating temperature of the second heating plate 21 is 245℃-255℃, thereby avoiding damage to the release film 13 while fully heating the second felt 16.

[0032] Step S8 involves pressing and molding the third felt material 34. (Refer to...) Figure 4As shown, a molding assembly is used to press and mold the third felt material 34. The molding assembly includes a drive mechanism 3, a base 31, a first pressure plate 32, and a second pressure plate 33. The drive mechanism 3 is a linear drive mechanism located above the base 31, with its execution end facing the base 31. The first pressure plate 32 is connected to the execution end of the drive mechanism 3, and the second pressure plate 33 is connected to the top side of the base 31. The third felt material 34 is placed on the second pressure plate 33, and then the drive mechanism 3 moves the first pressure plate 32, clamping the third felt material 34 between the first pressure plate 32 and the second pressure plate 33. The clamping sides of the first pressure plate 32 and the second pressure plate 33 are provided with protrusions and grooves corresponding to the product shape. Through the compression of the third felt material 34 by the first pressure plate 32 and the second pressure plate 33, the third felt material 34 is formed into the required shape of the product, thereby forming a flame-retardant part. To facilitate rapid shaping of the third felt 34, both the first pressure plate 32 and the second pressure plate 33 are connected to a mold temperature controller. The controller controls the temperature of the first and second pressure plates 32 and 33. When the third felt 34 is placed on the second pressure plate 33, it is still at a high temperature, while the first and second pressure plates 32 and 33 are at a low temperature. As the first and second pressure plates 32 and 33 compress the third felt 34, they also rapidly cool it, thus rapidly shaping the third felt 34. After the third felt 34 is formed, the first and second pressure plates 32 and 33 separate, and the mold temperature controller cools them. The first and second pressure plates 32 and 33 are maintained at 5℃-15℃ before compressing the third felt 34. This rapid cooling of the third felt 34 causes the molten low-melting-point fibers to re-solidify within the part structure, thus bonding the fibers within the part and providing a supporting effect.

[0033] Flame-retardant parts manufactured using the manufacturing method of a highly flame-retardant and formable felt according to the present invention have been tested by the UL94 test method and meet the requirements of UL94-V0 (vertical burning), that is, the flame-retardant parts are self-extinguishing when removed from the flame and do not melt and drip.

[0034] The present invention discloses a method for manufacturing a highly flame-retardant and formable felt. In step S5, the fiber web is punctured, causing the fibers in the loose fiber layer to entangle with each other, thereby improving the strength of the flame-retardant part. In step S7, the second felt material 16 is heated, causing the low-melting-point fibers in the second felt material 16 to melt, allowing the fibers inside the flame-retardant part to bond with each other, further improving the strength of the flame-retardant part. By improving the strength of the flame-retardant part and by using a mixture of flame-retardant fiber material and pre-oxidized fiber material, it is possible to maintain high flame-retardant requirements and reduce the weight of the flame-retardant part while reducing the amount of fiber material used.

[0035] Obviously, the above embodiments are merely illustrative examples for clear explanation and are not intended to limit the implementation. Those skilled in the art will recognize that other variations or modifications can be made based on the above description. It is neither necessary nor possible to exhaustively list all possible implementations here. However, obvious variations or modifications derived therefrom are still within the scope of protection of this invention.

Claims

1. A method for manufacturing a highly flame-retardant and formable felt, characterized in that, Includes the following steps: Step S1: Weigh the flame-retardant fiber material and the pre-oxidized fiber material and feed them in proportion. Step S2: Tear and mix the flame-retardant fiber material and the pre-oxidized fiber material until a mixture is formed; Step S3: Comb the mixture until a first fiber web is formed, consisting of multiple fibers facing the same direction; Step S4: Lay the first fiber web on the conveyor until the second fiber web is formed; Step S5: Puncture the second fiber web until the first felt is formed; Step S6: Apply a release film to the surface of the first felt material until the second felt material is formed; Step S7: Heat the second felt material until the low-melting-point fibers in the second felt material melt to form the third felt material; Step S8: Press the third felt material into shape.

2. The method for manufacturing highly flame-retardant and formable felt according to claim 1, characterized in that: In step S1, the flame-retardant fiber material is a low-melting-point flame-retardant fiber material, and the proportion of flame-retardant fiber material is 30%-50%, while the proportion of pre-oxidized fiber material is 50%-70%.

3. The method for manufacturing highly flame-retardant and formable felt according to claim 1, characterized in that: In step S2, the flame-retardant fiber material and the pre-oxidized fiber material are shredded into flocculent form and mixed.

4. The method for manufacturing highly flame-retardant and formable felt according to claim 1, characterized in that: In step S5, a needle with a barb hook is used to puncture the second fiber mesh.

5. The method for manufacturing highly flame-retardant and formable felt according to claim 1, characterized in that: In step S6, the separator is a nylon composite membrane.

6. The method for manufacturing highly flame-retardant and formable felt according to claim 1, characterized in that: In step S6, a film-applying assembly is set up to apply a release film to the first felt material. The film-applying assembly includes a first feeding roller, a second feeding roller, a driven roller, and a heating roller. The first feeding roller is used to transport the first felt material, and the second feeding roller is used to transport the release film. The release film is wrapped around the heating roller, and the first felt material passes between the driven roller and the heating roller and is applied to the release film.

7. The method for manufacturing highly flame-retardant and formable felt according to claim 1, characterized in that: In step S7, a heating assembly is set to heat the second felt material. The heating assembly includes a first heating plate and a second heating plate, and the second felt material is clamped between the first heating plate and the second heating plate.

8. The method for manufacturing highly flame-retardant and formable felt according to claim 7, characterized in that: The heating temperatures of the first heating plate and the second heating plate can be controlled independently.

9. The method for manufacturing highly flame-retardant and formable felt according to claim 1, characterized in that: In step S8, a molding assembly is set to press and mold the third felt material. The molding assembly includes a driving mechanism, a base, a first pressure plate and a second pressure plate. The first pressure plate is connected to the execution end of the driving mechanism, the second pressure plate is connected to the base, and the third felt material is clamped between the first pressure plate and the second pressure plate.

10. The method for manufacturing highly flame-retardant and formable felt according to claim 9, characterized in that: Both the first pressure plate and the second pressure plate are capable of cooling.

Images