A high-flatness flame-retardant support cloth and a preparation process thereof

Abstract

The application belongs to the technical field of textile composite fabrics, and particularly relates to a high-flatness flame-retardant support cloth and a preparation process thereof, which comprises a base cloth layer, an elastic stress balance layer and a flame-retardant layer which are integrated by an adhesive. The application solves the problems of easy wrinkling, concave-convex deformation, edge warping, poor flatness stability, and unbalanced flame-retardant and air-permeable flexibility of the existing support cloth, realizes the persistent stability of the high flatness of the support cloth, and is suitable for complex environments and high-precision processing scenes.

Description

Technical Field

[0001] This invention belongs to the field of textile composite fabric technology, and in particular to a high-flatness flame-retardant support fabric and its preparation process. Background Technology

[0002] As a functional composite fabric, textile support fabric is widely used in various fields such as industrial processing, protective equipment, and decorative substrates. During use, it not only needs to possess basic mechanical strength and flame-retardant protective properties, but also faces stringent requirements regarding surface smoothness, dimensional stability, flexibility, and breathability. Currently, most mainstream flame-retardant support fabrics on the market adopt a double-layer composite structure of a base fabric and a flame-retardant layer. Production processes mainly involve conventional weaving, full-page adhesive coating, and simple heat setting. However, under long-term use or complex working conditions such as alternating high and low temperatures, the fabric is prone to wrinkles, localized uneven deformation, and edge warping. Smoothness continuously deteriorates over time, and dimensional stability fails to meet the demands of high-precision processing scenarios.

[0003] The core reason for the above defects lies in the fact that traditional support fabrics fail to effectively control the internal stress of the fabric. On the one hand, the warp tension control precision during the weaving process is low, with tension fluctuations generally exceeding 10%, and the warp and weft density is uniform throughout the fabric, making it impossible to balance the stress distribution in the width direction, thus causing edge warping and local stress concentration problems. On the other hand, there is a large amount of residual internal stress between the layers of the double-layer composite structure. Existing products lack a dedicated stress buffer and compensation structure, and the residual stress generated by multiple processes such as weaving, lamination, and coating cannot be eliminated. Under the action of external force and temperature changes, it is gradually released, eventually leading to fabric deformation and deterioration of flatness. At the same time, traditional processes generally use full-area adhesive coating to achieve interlayer bonding. Although this can ensure the composite strength, it will significantly block the fabric pores, causing the fabric to become stiff and its breathability to drop significantly. This results in an imbalance between flame retardant properties and breathability and flexibility, seriously affecting the product's user experience and scope of application.

[0004] CN211683789U discloses a layered composite wrinkle-resistant textile fabric with a double-layer flame-retardant structure. The main body is composed of a base fabric and a flame-retardant surface layer. A simple elastic connecting structure is set between the two layers to improve the fabric's wrinkle resistance, while a flame-retardant coating gives the fabric fire-retardant properties. Although this solution combines the two functions of flame retardancy and wrinkle resistance, it improves the problems of easy wrinkling and lack of flame retardancy of traditional single-layer fabrics to some extent. However, relying solely on the double-layer structure and simple elastic connectors for wrinkle resistance, the fabric will still deform and lose smoothness after long-term use; the fabric adopts an overall full-coating composite process, and still suffers from poor breathability and a stiff feel; the dimensional heat shrinkage rate is relatively high, making it unsuitable for working conditions with high requirements for smoothness and dimensional accuracy.

[0005] Therefore, developing a flame-retardant support fabric with high flatness, low residual stress, and excellent flame retardancy, breathability, and flexibility, as well as its preparation process, has become a technical challenge that urgently needs to be solved in this field. Summary of the Invention

[0006] To address the shortcomings of the existing technologies, a high-flatness flame-retardant support fabric and its preparation process are provided. This solves the problems of easy wrinkling, uneven deformation, edge warping, poor flatness stability, and imbalance between flame retardancy and breathability in existing support fabrics. It achieves long-lasting stability of high flatness in the support fabric, making it suitable for complex environments and high-precision processing scenarios.

[0007] To solve the above-mentioned technical problems, the technical solution adopted by the present invention is a high-flatness flame-retardant support fabric, comprising a base fabric layer, an elastic stress balancing layer, and a flame-retardant layer integrally bonded by an adhesive. The elastic stress balancing layer is sandwiched between the base fabric layer and the flame-retardant layer. The elastic stress balancing layer is formed by weaving high-elasticity modulus fibers and low-elasticity modulus fibers, with an elastic modulus ratio of 1:3 to 1:7, to form a stress compensation effect and offset residual internal stress between layers. The support fabric has a density gradient structure along its width direction, with the warp and weft density in the middle of the fabric being greater than that at the edges, and the difference in surface density between the middle and the edges being controlled within 5% to 15%, achieving a uniform stress distribution throughout the entire area.

[0008] The aforementioned high-flatness flame-retardant support fabric has a base fabric layer made of high-strength polyester fiber with a breaking strength ≥8cN / dtex, which provides stable basic mechanical support strength and tensile properties for the composite support fabric and inhibits the decline in flatness during long-term use.

[0009] The high-flatness flame-retardant support fabric mentioned above uses high-elasticity modulus fiber made of glass fiber and low-elasticity modulus fiber made of polyurethane fiber. The two types of fibers are interwoven to form a stress-balanced structure with elastic deformation capability and stiffness matching characteristics.

[0010] The aforementioned high-flatness flame-retardant support fabric includes a flame-retardant layer that is a uniformly coated inorganic flame-retardant layer applied to the outer surface of the composite fabric. The inorganic flame-retardant is selected from phosphate esters or boron-based flame-retardants, and the coating amount per unit area is 20 g / m². 2 ~50g / m 2 While ensuring high flame retardant performance, it retains the original flexibility and smoothness of the fabric.

[0011] The aforementioned high-flatness flame-retardant support fabric, wherein the base fabric layer, elastic stress balance layer, and flame-retardant layer are all bonded and fixed using a dot-matrix adhesive coating composite process; the adhesive dots are evenly arrayed, with a spacing of 5mm to 10mm, and the adhesive application amount per unit area is controlled at 5g / m². 2~15g / m 2 This ensures both the bonding strength and integrity between the layers, while also preserving the breathability and softness of the fabric.

[0012] The above-mentioned process for preparing a high-flatness flame-retardant support fabric includes the following steps:

[0013] S1. Base fabric weaving: High-strength polyester fibers with a breaking strength ≥8cN / dtex are selected as the weaving raw material, and the warp tension fluctuation range is strictly controlled within ±5%. At the same time, the fabric is woven according to the width-density gradient process, and the density in the middle of the fabric is controlled to be 5% to 15% higher than the edge density, so as to eliminate the defects of fabric edge warping and local stress concentration, and obtain a base fabric layer with high uniformity and low residual stress.

[0014] S2. Elastic stress balance layer weaving: Glass fiber and polyurethane fiber are selected as raw materials, and the warp and weft are interwoven strictly according to the stiffness matching ratio of 1:3 to 1:7 to prepare an elastic stress balance layer with bidirectional stress compensation function, which can actively offset the internal stress generated in the base fabric layer and composite molding process.

[0015] S3. Dot-matrix layered composite molding: Using a dot-matrix array adhesive coating process, environmentally friendly adhesive is evenly applied to the upper surface of the base fabric layer and the upper and lower surfaces of the elastic stress balance layer, controlling the spacing between adhesive dots to be 5mm-10mm and the adhesive application rate to be 5g / m². 2 ~15g / m 2 The base fabric layer, elastic stress balance layer, and flame-retardant substrate are sequentially stacked and uniformly pressed together using a pressing device to form a composite fabric without voids or delamination.

[0016] S4. Heat setting treatment: The pressed composite fabric is sent into the heat setting equipment and kept at a constant temperature of 160℃~200℃ for 30s~120s to allow the fiber molecular chains inside the fabric to fully relax and rearrange themselves, eliminating the residual forming stress generated by the weaving and composite processes; after the heat setting is completed, it is naturally cooled to room temperature to lock in the flat shape of the fabric and improve the overall dimensional stability.

[0017] S5. Flame-retardant coating curing treatment: On the outer surface of the shaped composite fabric, a phosphate ester or boron-based inorganic flame retardant is uniformly coated, with the coating amount strictly controlled to be 20g / m². 2 ~50g / m 2 After drying and curing, a uniform, wear-resistant, and flame-retardant coating is formed on the fabric surface, which does not affect the flatness, and finally a flame-retardant support fabric with high flatness and high dimensional stability is obtained.

[0018] In the above-mentioned high-flatness flame-retardant support fabric preparation process, in step S3, the lamination and pressing pressure is controlled at 0.2MPa to 0.5MPa, and the pressing speed is 2m / min to 5m / min to ensure uniform bonding of each layer and tight structure, and to prevent local voids and interlayer misalignment.

[0019] According to the above-mentioned preparation process of high-flatness flame-retardant support fabric, in step S5, the drying and curing temperature of the flame-retardant coating is 80℃~120℃, and the curing and heat preservation time is 5min~15min, to ensure that the flame-retardant coating is fully cured and firmly adhered, and to avoid coating peeling and wrinkling that affect the flatness of the fabric.

[0020] The beneficial effects of the high flatness flame-retardant support fabric and its preparation process of the present invention are that it adopts a three-layer composite structure and adds an elastic stress balance layer to solve the stress defects of traditional single-layer and double-layer structures. By matching the stiffness of high and low modulus fibers to form a stress compensation system, it can actively offset the internal stress of the fabric and solve the problems of wrinkles and uneven deformation under long-term use and temperature change environment from the root, thus improving the flatness and stability over time.

[0021] By controlling tension fluctuations within ±5% and regulating the density distribution across the entire area, the problems of uneven tension, edge warping, and local unevenness in traditional weaving are solved, resulting in a fabric with better overall flatness and uniformity than conventional products.

[0022] By defining precise heat setting process parameters, residual stress is eliminated through high-temperature molecular chain rearrangement, the fabric's flat shape is fixed, the fabric's dimensional stability is improved, shape distortion is avoided during subsequent processing and use, and long-term flatness consistency is guaranteed.

[0023] The dot-matrix adhesive coating process, compared to the traditional full-page adhesive coating, effectively preserves the breathability and flexibility of the fabric while ensuring strong interlayer adhesion and eliminating delamination and hollow areas. This improves the comfort of the product and solves the defects of traditional composite fabrics, such as stiffness and poor breathability.

[0024] The high-strength polyester base fabric and quantitative inorganic flame-retardant coating not only ensure the fabric's excellent mechanical strength and service life, but also achieve stable flame-retardant performance. Furthermore, the flame-retardant coating is thin and uniform, and will not damage the fabric's flat shape, thus taking into account structural strength, safety protection, and appearance quality. Attached Figure Description

[0025] Figure 1 This is a process flow diagram for preparing a high-flatness flame-retardant support fabric according to the present invention. Detailed Implementation

[0026] The present invention will now be described in detail with reference to the accompanying drawings and specific embodiments.

[0027] Example 1

[0028] like Figure 1 As shown, a preparation process for a high-flatness flame-retardant support fabric includes the following specific steps:

[0029] S1. Base fabric weaving: Polyester fiber with a breaking strength of 8cN / dtex is selected. Tension sensors are used for real-time monitoring and servo motors for dynamic adjustment to control warp tension fluctuations within ±3%. During weaving, the density in the middle of the fabric is controlled to be 8% higher than that at the edge to obtain a uniform base fabric layer.

[0030] S2. Elastic stress balance layer weaving: Glass fiber and polyurethane fiber are selected and interwoven at a stiffness ratio of 1:4 to prepare an elastic stress balance layer.

[0031] S3. Dot-matrix layered composite molding: Dot-matrix adhesive application is used, with a dot spacing of 6mm and an adhesive application rate of 8g / m³. 2 The base fabric layer, stress balance layer, and flame-retardant substrate are sequentially laminated and pressed together under a pressure of 0.3 MPa and a speed of 3 m / min; the adhesive is a water-based polyurethane environmentally friendly adhesive for textiles.

[0032] S4. Heat setting and shaping treatment: The composite blank is placed in an environment of 180℃ and kept at that temperature for 60 seconds, then naturally cooled and shaped.

[0033] S5. Flame-retardant coating curing treatment: Apply boron-based flame retardant, coating amount 35g / m². 2 Dry and cure at 100℃ for 10 minutes to obtain the finished support fabric.

[0034] Example 2

[0035] A process for preparing a high-flatness flame-retardant support fabric, the specific steps of which are as follows:

[0036] S1. Base fabric weaving: Polyester fiber with a breaking strength of 8.5 cN / dtex is selected, the warp tension fluctuation is controlled at ±4%, and the density in the middle of the fabric is 10% higher than that at the edge to weave the base fabric layer.

[0037] S2, Elastic stress balance layer weaving: Glass fiber and polyurethane fiber are interwoven at a stiffness ratio of 1:5;

[0038] S3. Dot-matrix layered composite molding: 8mm spacing between adhesive dots, 10g / m² of adhesive applied. 2 Pressing at 0.4 MPa pressure and 4 m / min speed;

[0039] S4. Heat setting and shaping treatment: Hold at 170℃ for 90 seconds, then allow to cool and set naturally.

[0040] S5. Flame-retardant coating curing treatment: Apply phosphate ester flame retardant, coating amount 40g / m². 2 Dry and cure at 90℃ for 12 minutes to obtain the finished product.

[0041] Example 3

[0042] A process for preparing a high-flatness flame-retardant support fabric, the specific steps of which are as follows:

[0043] S1. Base fabric weaving: Polyester fiber with a breaking strength of 9cN / dtex is selected, and the warp tension fluctuation is controlled within ±5%. The density in the middle of the fabric is 12% higher than that at the edge to weave the base fabric layer.

[0044] S2, Elastic stress balance layer weaving: Glass fiber and polyurethane fiber are interwoven at a stiffness ratio of 1:6;

[0045] S3. Dot-matrix layered composite molding: Glue dot spacing 10mm, glue application amount 12g / m 2 Pressing at 0.5MPa pressure and 5m / min speed;

[0046] S4. Heat setting and shaping treatment: Hold at 190℃ for 40 seconds, then allow to cool and set naturally.

[0047] S5. Flame-retardant coating curing treatment: Apply boron-based flame retardant, coating amount 45g / m². 2 Dry and cure at 110℃ for 8 minutes to obtain the finished product.

[0048] Comparative Example

[0049] Traditional double-layer support fabric: adopts a double-layer structure of conventional base fabric and flame-retardant layer, adjusts warp tension with ordinary machinery (tension fluctuation > 10%), weaves with uniform density, applies adhesive to the entire fabric, and heat-sets at 150℃ for 150s. The remaining raw materials and flame-retardant process are the same as in Example 1.

[0050] Performance test results:

[0051] Flatness, dimensional stability, flame retardancy, and air permeability tests were conducted on the products of each embodiment and comparative example. The results are as follows:

[0052] 1. Flatness: The surface of the products in Examples 1-3 of this invention is free of wrinkles, bumps, and edge warping. After high and low temperature cycling tests, the flatness does not decrease significantly. The comparative products show slight wrinkles and edge warping after 30 days of use, and the flatness decreases significantly.

[0053] 2. Dimensional stability: The heat shrinkage rate of the product of this invention is ≤0.5%, while the heat shrinkage rate of the comparative example is ≥1.8%;

[0054] 3. Flame retardant performance: The flame retardant rating of the products of this invention all reach V0 level, which is comparable to the flame retardant performance of the comparative examples.

[0055] 4. Breathability: The dot-coating process of this invention increases the air permeability by more than 40% compared with the full-page coating process of the comparative method, and the fabric has better flexibility.

[0056] As can be seen, this invention improves the flatness and dimensional stability of the support fabric while ensuring excellent flame retardant performance and mechanical strength, and optimizes breathability and flexibility. Its overall performance is far superior to that of traditional products.

[0057] The above description is only a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. A high-flatness flame-retardant support fabric, characterized in that: The fabric comprises a base fabric layer, an elastic stress balancing layer, and a flame-retardant layer, all bonded together by an adhesive. The elastic stress balancing layer is sandwiched between the base fabric layer and the flame-retardant layer. The elastic stress balancing layer is formed by interlacing high-elasticity modulus fibers and low-elasticity modulus fibers, with an elastic modulus ratio of 1:3 to 1:7, to create a stress compensation effect and offset residual internal stress between layers. The supporting fabric has a density gradient structure along its width, with the warp and weft density in the middle of the fabric being greater than that at the edges, and the difference in surface density between the middle and the edges being controlled within 5% to 15%, achieving a balanced stress distribution throughout the fabric.

2. The high-flatness flame-retardant support fabric according to claim 1, characterized in that, The base fabric layer is made of high-strength polyester fiber with a breaking strength of ≥8cN / dtex woven in warp and weft.

3. The high-flatness flame-retardant support fabric according to claim 1, characterized in that, The high-elasticity modulus fiber is glass fiber, and the low-elasticity modulus fiber is polyurethane fiber.

4. The high flatness flame-retardant support fabric according to claim 1, characterized in that, The flame-retardant layer is an inorganic flame-retardant coating uniformly applied to the outer surface of the composite fabric. The inorganic flame-retardant is selected from phosphate ester flame retardants or boron-based flame retardants, and the coating amount per unit area is 20 g / m². 2 ~50g / m 2 .

5. The high-flatness flame-retardant support fabric according to claim 4, characterized in that, The base fabric layer, elastic stress balance layer, and flame retardant layer are all bonded and fixed together using a dot-matrix adhesive coating process; the adhesive dots are evenly distributed in an array, with a spacing of 5mm to 10mm between the dots, and the adhesive application rate per unit area is controlled at 5g / m². 2 ~15g / m 2 .

6. The preparation process of a high-flatness flame-retardant support fabric according to any one of claims 1-5, characterized in that, Includes the following steps: S1. Base fabric weaving: High-strength polyester fibers with a breaking strength ≥8cN / dtex are selected as the weaving raw material, and the warp tension fluctuation range is strictly controlled within ±5%. At the same time, the fabric is woven according to the width-density gradient process, and the density in the middle of the fabric is controlled to be 5% to 15% higher than the edge density, so as to eliminate the defects of fabric edge warping and local stress concentration, and obtain a base fabric layer with high uniformity and low residual stress. S2. Elastic stress balance layer weaving: Glass fiber and polyurethane fiber are selected as raw materials, and the warp and weft are interwoven strictly according to the stiffness matching ratio of 1:3 to 1:7 to prepare an elastic stress balance layer with bidirectional stress compensation function. S3. Dot-matrix layered composite molding: Using a dot-matrix array coating process, environmentally friendly adhesive is evenly applied to the upper surface of the base fabric layer and the upper and lower surfaces of the elastic stress balance layer, respectively, controlling the spacing between coating dots to be 5mm to 10mm and the amount of adhesive applied per unit area to be 5g / m² to 15g / m²; the base fabric layer, elastic stress balance layer and flame-retardant substrate are sequentially stacked and evenly pressed together by a pressing equipment to form a composite fabric without voids or delamination. S4. Heat setting treatment: The pressed composite fabric is sent into the heat setting equipment and kept at a constant temperature of 160℃~200℃ for 30s~120s to allow the fiber molecular chains inside the fabric to fully relax and rearrange themselves. After the heat setting is completed, the fabric is naturally cooled to room temperature to lock in the flat shape of the fabric. S5. Flame-retardant coating curing treatment: On the outer surface of the shaped composite fabric, a phosphate ester or boron-based inorganic flame retardant is uniformly coated, with the coating amount strictly controlled to be 20g / m². 2 ~50g / m 2 ; After drying and curing, a uniform, wear-resistant, and flame-retardant coating is formed on the fabric surface, which does not affect the flatness, and finally a flame-retardant support fabric with high flatness and high dimensional stability is obtained.

7. The preparation process of the high-flatness flame-retardant support fabric according to claim 6, characterized in that: In step S3, the lamination pressure is controlled at 0.2MPa to 0.5MPa, and the lamination speed is 2m / min to 5m / min.

8. The preparation process of the high-flatness flame-retardant support fabric according to claim 7, characterized in that: The preparation process of the high flatness flame-retardant support cloth according to claim 6 is characterized in that: in step S5, the drying and curing temperature of the flame-retardant coating is 80℃~120℃, and the curing and heat preservation time is 5min~15min.

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