Basalt fiber fireproof composite material for soft home decoration and preparation method and application thereof

Abstract

This invention relates to a basalt fiber fire-retardant composite material for upholstered furniture, its preparation method, and its application, belonging to the field of flame-retardant materials technology. The composite material comprises, from top to bottom, a first flame-retardant needle-punched cotton layer, a basalt fiber cloth layer, and a second flame-retardant needle-punched cotton layer. The first flame-retardant needle-punched cotton layer and the basalt fiber cloth layer are bonded together via discrete hot-melt bonding to form an array of bonding nodes. The unbonded areas constitute hollow, heat-insulating microcavities with a thickness-direction clearance of 0.5~2.0 mm. The basalt fiber cloth layer and the second flame-retardant needle-punched cotton layer form a continuous bonding interface. This composite material combines excellent fire resistance, heat insulation, and flexibility, making it suitable for flame-retardant protective layers or padding materials in upholstered furniture.

Description

Technical Field

[0001] This invention relates to the field of fire-retardant materials for upholstered home decoration, specifically to a basalt fiber fire-retardant composite material for upholstered home decoration, its preparation method, and its application. Background Technology

[0002] With increasing demands for home safety, the fire resistance of upholstered furniture (such as sofas, mattresses, and chairs) has become a key indicator in product design. To meet relevant fire safety standards (such as GB 17927 and CAL 117), current technologies typically incorporate a flame-retardant layer within upholstered furniture to slow the spread of flames and inhibit heat transfer to the internal sponge or filling materials. Currently, commonly used fire-resistant composite materials often employ fiberglass cloth, aramid fiber felt, or metallized fabrics as the core flame-retardant layer, combined with flexible materials such as flame-retardant needle-punched cotton and non-woven fabrics. However, in practical applications, such materials generally suffer from the problem of not being able to balance softness and comfort with fire resistance: although fiberglass cloth has excellent high temperature resistance and flame retardancy, it is hard and brittle with poor resilience, which can easily lead to a stiff and uncomfortable feeling when it comes into direct contact with the human body or is used to cover the surface of a cushion; while using soft materials such as flame-retardant needle-punched cotton can improve comfort, but its heat insulation capacity is limited. In the early stages of a fire, it cannot effectively block the rapid penetration of heat, causing the flammable sponge inside to heat up and ignite rapidly, making it difficult to meet high-level fire protection requirements.

[0003] Furthermore, existing fire-resistant composite materials are prone to interlayer separation and "air gaps" during dynamic use. Upholstered furniture is frequently subjected to bending, compression, and rebound forces during daily use. If the functional layers are only bonded together through integral hot pressing or adhesive bonding, the interfacial bond between the rigid flame-retardant layer (such as fiberglass cloth) and the flexible filler layer is easily compromised by repeated deformation, leading to localized delamination, wrinkling, or the formation of hollow areas. This not only damages the overall structural integrity of the material but also creates heat conduction channels at the delamination points, significantly weakening the fire barrier effect and affecting the uniformity of seating comfort and product lifespan.

[0004] More importantly, existing technologies lack the active structural utilization of the air thermal barrier effect. Air itself is an excellent thermal insulator, but traditional fire-resistant composite materials mostly rely on static thermal barrier mechanisms of single components (such as dense fiber layers or metal reflective layers), without constructing controllable hollow thermal insulation microcavities at the microstructural level. Especially when it is necessary to balance the contradictory requirements of "reliable interlayer bonding" and "maintaining effective thermal insulation gaps," existing solutions often suffer from one problem at the expense of the other—excessive bonding can ensure structural stability, but it compresses the air layer space and reduces thermal insulation efficiency; while reducing bonding can easily lead to the aforementioned interlayer separation problem.

[0005] In recent years, basalt fiber has been gradually introduced into the field of fireproof materials due to its natural inorganic components, high melting point (>1000℃), excellent flame retardancy (Class A non-combustible), good flexibility, and environmentally friendly biodegradability. For example, CN106337508A discloses a thermal insulation layer structure with basalt fiber woven fabric or needle-punched felt composited on both sides of a foam substrate, used to improve the fire resistance and sound insulation performance of building insulation systems; CN110626012B proposes a non-combustible board made of multiple layers of basalt fiber mesh, fabric, and felt, which has wear resistance, smoke resistance, and a high fire resistance rating; CN217917081U further combines basalt fiber cloth with aerogel and ceramic fiber paper to prepare a high-performance fireproof felt with a temperature resistance of over 1400℃. Furthermore, CN119567648A and CN119659107A respectively use basalt fiber cloth to reinforce needle-punched felt or as the core insulation layer of fireproof roller shutters, improving overall performance through impregnation modification or blending with other refractory fibers. Although the aforementioned literature demonstrates the application potential of basalt fiber in fireproofing and insulation, its structural design still focuses on static composite and overall densification, failing to address the unique "comfort-fireproof-durability" synergistic needs of upholstered furniture. It does not propose a composite material solution that maintains a soft touch, achieves dynamic insulation through structured microcavities, and ensures stable interlayer bonding. In particular, the lack of a systematic design for the synergistic configuration of discrete bonding nodes and hollow insulation microcavities makes it difficult to resolve the aforementioned technical contradictions. Summary of the Invention

[0006] To address the technical challenges of existing fire-resistant composite materials for upholstered home furnishings, such as the difficulty in balancing softness and comfort with fire resistance, the susceptibility to interlayer separation and delamination during dynamic use, and the lack of a dynamic heat insulation mechanism that actively utilizes the air thermal barrier, this paper proposes a basalt fiber fire-resistant composite material for upholstered home furnishings. This material should possess excellent compression resilience, stable and reliable interlayer bonding, and dual functions of mechanical cushioning and thermal barrier, while meeting the comprehensive requirements of upholstered home furnishings for flame retardant safety and ride comfort.

[0007] The objective of this invention is achieved through the following technical solution: a basalt fiber fireproof composite material for soft home decoration, wherein the basalt fiber fireproof composite material comprises, from top to bottom along the thickness direction, a first flame-retardant needle-punched cotton layer, a basalt fiber cloth layer, and a second flame-retardant needle-punched cotton layer; the first flame-retardant needle-punched cotton layer and the basalt fiber cloth layer are bonded together by discrete hot-melt bonding to form an array of bonding nodes, and the unbonded areas constitute hollow heat-insulating microcavities; the basalt fiber cloth layer and the second flame-retardant needle-punched cotton layer are bonded together by full-area composite bonding or local spot bonding to form a continuous bonding interface.

[0008] Preferably, the bonding area ratio of the discrete hot melt adhesive is 15% to 25%, based on the total area of ​​the first flame-retardant needle-punched cotton layer.

[0009] Preferably, the net height of the hollow thermal insulation microcavity in the thickness direction is 0.5~2.0 mm.

[0010] Preferably, the arrayed bonding nodes are arranged in a square dot matrix, a rectangular dot matrix, or a rhombus dot matrix.

[0011] Preferably, the diameter of the arrayed bonding nodes is 1.5~3.0 mm, and the center-to-center distance between the bonding nodes is 6.0~12.0 mm.

[0012] Preferably, the unbonded area between the first flame-retardant needle-punched cotton layer and the basalt fiber cloth layer has an out-of-plane convex configuration in the thickness direction, forming a hollow heat-insulating microcavity with closed or semi-closed characteristics.

[0013] Preferably, the unit area mass of the first flame-retardant needle-punched cotton layer is 60 g / m². 2 ~200 g / m 2 .

[0014] Preferably, the basalt fiber cloth layer has a unit area mass of 200 g / m². 2 ~800 g / m 2 .

[0015] Preferably, the unit area mass of the second flame-retardant needle-punched cotton layer is 60 g / m². 2 ~200 g / m 2 .

[0016] Preferably, the thickness of the first flame-retardant needle-punched cotton layer is 0.5~5.0 mm.

[0017] Preferably, the thickness of the basalt fiber cloth layer is 0.2~2 mm.

[0018] Preferably, the thickness of the second flame-retardant needle-punched cotton layer is 0.5~5.0 mm.

[0019] This invention also provides a method for preparing a basalt fiber fire-resistant composite material for upholstered home decoration, comprising the following steps: S1. Weigh out a unit area mass of 60 g / m². 2 ~200 g / m 2 The first flame-retardant needle-punched cotton layer has a unit area mass of 200 g / m². 2 ~800 g / m 2 The basalt fiber cloth layer has a unit area mass of 60 g / m³. 2 ~200 g / m 2 The second flame-retardant needle-punched cotton layer, and a unit area mass of 40 g / m 2Low-melting-point PET hot melt adhesive mesh; lay the PET hot melt adhesive mesh flat between the first flame-retardant needle-punched cotton layer and the basalt fiber cloth layer, and then stack them neatly in the order of the first flame-retardant needle-punched cotton layer, the basalt fiber cloth layer, and the second flame-retardant needle-punched cotton layer, ensuring that the edges of each layer are aligned and without wrinkles, for later use. S2. Place the stacked material from step S1 between the lower and upper pressing plates of a flat hot press with dot matrix punches for local hot pressing. The punch array applies local pressure in the contact area to melt the low-melting-point PET hot melt adhesive mesh and form discrete bonding nodes after cooling and solidification. S3. Take out the composite material after hot pressing in step S2 and let it cool naturally at room temperature (20~25℃) for 4~6 minutes, or use forced convection cooling (room temperature wind, wind speed 2 m / s) for 2~3 minutes to completely solidify and shape the PET hot melt adhesive mesh and form a strong bonding node; finally, cut it according to the required size of the soft home decoration, and check that the bonding nodes are evenly distributed, without delamination or holes, to obtain the finished basalt fiber fireproof composite material.

[0020] Preferably, the feature is that in step S1, the melting point of the PET hot melt adhesive mesh is 110~130℃.

[0021] Preferably, the process parameters for the local hot pressing in step S2 are: hot pressing temperature 130℃~140℃, hot pressing pressure 0.38 MPa~0.42 MPa, and holding time 4 s; During hot pressing, the punch array compacts the first flame-retardant needle-punched cotton layer and the basalt fiber cloth layer at the point contact area. The low-melting-point PET hot melt adhesive mesh melts upon heating and forms a strong bonding node after cooling. The areas not pressed by the punch remain separated, forming a hollow heat-insulating microcavity with a net height of 0.5 mm to 2.0 mm.

[0022] Preferably, in step S2, the punch unit of the dot matrix punch is a cylindrical boss with a diameter of 3.0 mm, a height of 2.0 mm, a center distance of 6.0 mm, and arranged in a rectangular grid array (row spacing 6 mm, column spacing 6 mm).

[0023] The present invention also provides an application of basalt fiber fireproof composite material for upholstered home decoration, wherein the basalt fiber fireproof composite material is used as a flame-retardant protective layer or flame-retardant lining material in upholstered home decoration.

[0024] The beneficial effects of this invention are as follows: Compared with the prior art, this invention constructs a hollow heat-insulating microcavity defined by discrete bonding nodes between the first flame-retardant needle-punched cotton layer and the basalt fiber cloth layer, thus realizing a "dynamic air heat insulation mechanism" for the first time. Under normal conditions, the static air in the microcavity provides an efficient heat insulation barrier; when compressed, the microcavity exhausts air to maintain a soft touch; after unloading, it automatically draws back air to restore its heat insulation function, thereby breaking through the technical bottleneck of traditional static barrier materials where "gap loss occurs when connected, and instability occurs when gaps are left." Compression rebound tests show that after 500 compression cycles at 50% thickness, the thickness recovery rate is ≥93%, significantly better than the irreversible deformation of glass fiber cloth-based composite materials; the oxygen index is ≥30%, meeting the flame retardant Class 1 requirements of GB 20286-2006; in the butane torch (800℃) flame test, the time required for the temperature on the back of the lower layer to rise to 100℃ is ≥60 seconds, and there is no smoldering or reignition phenomenon, proving that its fireproof and heat-insulating performance is better than that of single-layer glass fiber cloth or all-cotton structures. Meanwhile, the bonding area ratio is controlled at 15%~25%, ensuring interlayer bonding strength while allowing free deformation of unbonded areas. No interlayer separation, wrinkling, or "air stretching" was observed in actual curling / bending tests, significantly improving dynamic stability during use. Furthermore, the raw materials used in this invention are all commercially available standard specifications, requiring no special modification. Compared to ceramic fiber cloth solutions, the cost is reduced by 30%~50%, and it can be directly adapted to existing upholstered home decoration production lines without the need for additional specialized equipment, demonstrating significant industrialization advantages. Attached Figure Description

[0025] Figure 1 This is a schematic diagram of the structure of the composite material of the present invention; Figure 2 This is a schematic diagram of the partial bonding of the composite material of the present invention; Figure 3 This is a schematic diagram of the stress state of the composite material of the present invention; Figure 4 This is a schematic diagram illustrating the principle of fire insulation of the composite material of the present invention.

[0026] The attached figures are labeled as follows: 1-first flame-retardant needle-punched cotton layer, 2-basalt fiber cloth layer, 3-second flame-retardant needle-punched cotton layer, 4-arrayed bonding nodes, 5-hollow heat-insulating microcavities, 6-substrate. Detailed Implementation

[0027] To facilitate understanding by those skilled in the art, the present invention will be further described below with reference to embodiments and accompanying drawings. The content mentioned in the embodiments is not intended to limit the present invention.

[0028] Example 1 See Figure 1-4 , A basalt fiber fireproof composite material for upholstered home decoration comprises, from top to bottom along the thickness direction, a first flame-retardant needle-punched cotton layer 1, a basalt fiber cloth layer 2, and a second flame-retardant needle-punched cotton layer 3. The first flame-retardant needle-punched cotton layer 1 and the basalt fiber cloth layer 2 are bonded together by discrete hot-melt bonding to form an array of bonding nodes 4. The unbonded areas exhibit an out-of-plane convex configuration in the thickness direction, forming hollow heat-insulating microcavities 5 with closed or semi-closed characteristics. The basalt fiber cloth layer 2 and the second flame-retardant needle-punched cotton layer 3 are bonded together using a full-area composite method to form a continuous bonding interface.

[0029] The unit area mass of the first flame-retardant needle-punched cotton layer 1 is 60 g / m². 2 ~200 g / m 2 The thickness ranges from 0.5 mm to 5.0 mm; the unit area mass of basalt fiber cloth layer 2 is 200 g / m². 2 ~800 g / m 2 The thickness is 0.2 mm to 2.0 mm; the unit area mass of the second flame-retardant needle-punched cotton layer 3 is 60 g / m². 2 ~200 g / m 2 The thickness ranges from 0.5 mm to 5.0 mm.

[0030] The bonding area ratio of discrete hot-melt bonding is 15%–25%, calculated based on the total area of ​​the first flame-retardant needle-punched cotton layer 1. The net height of the hollow thermal insulation microcavity 5 in the thickness direction is 0.5 mm–2.0 mm. The arrayed bonding nodes 4 are arranged in a rectangular lattice, with node diameters of 1.5 mm–3.0 mm and center-to-center distances of 6.0 mm–12.0 mm.

[0031] In one specific implementation, the unit area mass of the first flame-retardant needle-punched cotton layer 1 is 150 g / m². 2 The thickness is 3.0 mm; the unit area mass of basalt fiber cloth layer 2 is 500 g / m². 2 The thickness is 1.0 mm; the unit area mass of the second flame-retardant needle-punched cotton layer 3 is 150 g / m². 2 The thickness is 3.0 mm. The bonding nodes are circular dots with a diameter of 3.0 mm and a center-to-center distance of 6.0 mm, arranged in a rectangular dot matrix. The calculated bonding area ratio is approximately 19.6%, falling within the range of 15% to 25%. The net height of the hollow insulating microcavity 5 is controlled at 2.0 mm.

[0032] In another specific implementation, the unit area mass of the first flame-retardant needle-punched cotton layer 1 is 60 g / m². 2 The thickness is 0.5 mm; the unit area mass of basalt fiber cloth layer 2 is 200 g / m². 2The thickness is 0.2 mm; the unit area mass of the second flame-retardant needle-punched cotton layer 3 is 60 g / m². 2 The thickness is 0.5 mm. The diameter of the bonding nodes is 1.5 mm, the center distance is 12.0 mm, and they are arranged in a diamond lattice. The bonding area ratio is about 15.4%, and the net height of the hollow thermal insulation microcavity 5 is 0.5 mm.

[0033] In yet another specific implementation, the unit area mass of the first flame-retardant needle-punched cotton layer 1 is 200 g / m². 2 The thickness is 5.0 mm; the unit area mass of basalt fiber cloth layer 2 is 800 g / m². 2 The thickness is 2.0 mm; the unit area mass of the second flame-retardant needle-punched cotton layer 3 is 200 g / m². 2 The thickness is 5.0 mm. The diameter of the bonding nodes is 2.5 mm, the center distance is 9.0 mm, and they are arranged in a square lattice. The bonding area ratio is approximately 22.1%, and the net height of the hollow thermal insulation microcavity 5 is 1.2 mm.

[0034] Under normal use, when subjected to vertical pressure, the hollow heat-insulating microcavity 5 between the first flame-retardant needle-punched cotton layer 1 and the basalt fiber cloth layer 2 is compressed, expelling air and reducing the overall thickness, providing a soft and comfortable feel. After the pressure is released, air re-enters due to the resilience of the needle-punched cotton and the recovery ability of the microcavity structure, and the material returns to its original thickness. During repeated bending, curling, or compression, the microcavity structure absorbs deformation stress, preventing interlayer separation or wrinkling. In the event of fire, the first flame-retardant needle-punched cotton layer 1 initially provides flame retardancy. The static air layer within the hollow heat-insulating microcavity 5 effectively slows heat conduction inward due to its low thermal conductivity. The basalt fiber cloth layer 2, acting as a high-temperature resistant skeleton (withstanding 600℃~800℃), blocks flame penetration. The three elements work together to form a dynamic air heat insulation buffer mechanism, significantly delaying heat transfer to the lower filling sponge and improving fire safety performance.

[0035] Example 2 A method for preparing a basalt fiber fire-resistant composite material for upholstered home decoration includes the following steps: S1: Material stacking: Weigh a unit area mass of 60 g / m² 2 ~200 g / m 2 The first flame-retardant needle-punched cotton layer 1 has a unit area mass of 200 g / m². 2 ~800 g / m 2 2. Basalt fiber cloth layer with a unit area mass of 60 g / m 2 ~200 g / m 2 The second flame-retardant needle-punched cotton layer 3, and the unit area mass of 40 g / m 2The low-melting-point PET hot melt adhesive mesh is laid flat between the first flame-retardant needle-punched cotton layer 1 and the basalt fiber cloth layer 2, and then stacked neatly in the order of the first flame-retardant needle-punched cotton layer 1, the basalt fiber cloth layer 2, and the second flame-retardant needle-punched cotton layer 3, ensuring that the edges of each layer are aligned and without wrinkles, for later use; this stacked structure is consistent with the three-layer structure described in Example 1, wherein the first flame-retardant needle-punched cotton layer 1 and the basalt fiber cloth layer 2 form a hollow heat-insulating microcavity 5 through discrete bonding, and the basalt fiber cloth layer 2 and the second flame-retardant needle-punched cotton layer 3 form a continuous bonding interface through whole-area composite; S2: Local hot pressing: The materials stacked in step S1 are placed between the lower and upper pressing plates of a flatbed hot press with a dot matrix punch for local hot pressing. The hot pressing temperature is 130℃~140℃, the hot pressing pressure is 0.38 MPa~0.42 MPa, and the holding time is 4 s. The punch unit of the dot matrix punch is a cylindrical boss with a diameter of 3.0 mm, a boss height of 2.0 mm, and a boss center distance of 6.0 mm, arranged in a rectangular grid array. During the hot pressing process, the punch array applies local pressure to the contact area, causing the low melting point PET hot melt adhesive mesh to melt at a melting point of 110~130℃, and forming discrete bonding nodes after cooling. The areas not pressed by the punch remain separated, forming a hollow heat-insulating microcavity 5 with a net height of 0.5 mm~2.0 mm. S3: Cooling, Shaping and Cutting: Take out the composite material after hot pressing in step S2 and let it cool naturally at room temperature (20~25℃) for 4~6 minutes, or use forced convection cooling (room temperature wind, wind speed 2 m / s) for 2~3 minutes to completely solidify and shape the PET hot melt adhesive mesh and form a strong bonding node; then cut it according to the required size of the soft home decoration. After checking that the bonding nodes are evenly distributed, without delamination or holes, the finished basalt fiber fireproof composite material is obtained.

[0036] In one specific implementation, the unit area mass of the first flame-retardant needle-punched cotton layer 1 is 150 g / m². 2 The unit area mass of basalt fiber cloth layer 2 is 500 g / m². 2 The unit area mass of the second flame-retardant needle-punched cotton layer 3 is 150 g / m². 2 The unit area mass of PET hot melt adhesive mesh is 40 g / m². 2The melting point is 120℃; the hot-pressing temperature is set at 135℃, the pressure at 0.4MPa, and the holding time at 4 seconds; the punch array is a rectangular lattice with a diameter of 3.0 mm and a center-to-center distance of 6.0 mm, forming a bonding node area ratio of approximately 19.6%; the hollow heat-insulating microcavity 5 has a net height of 2.0 mm. After compression and rebound testing, the thickness recovery rate is ≥93% after 500 compressions to 50% of the original thickness; after flame heat insulation testing, when vertically burned with an 800℃ butane torch, the time required for the back surface temperature to rise from 25℃ to 100℃ is ≥60 seconds, with no smoldering or reignition.

[0037] In another specific implementation, the unit area mass of the first flame-retardant needle-punched cotton layer 1 is 60 g / m². 2 The unit area mass of basalt fiber cloth layer 2 is 200 g / m². 2 The unit area mass of the second flame-retardant needle-punched cotton layer 3 is 60 g / m². 2 The hot-pressing parameters are the same as above, the diameter of the bonding node is 3.0 mm, the center distance is 6.0 mm, the bonding area ratio is still 19.6%, and the net height of the hollow thermal insulation microcavity 5 is controlled to be 0.5 mm, which meets the microcavity height range defined in the claims.

[0038] In yet another specific implementation, the unit area mass of the first flame-retardant needle-punched cotton layer 1 is 200 g / m². 2 The unit area mass of basalt fiber cloth layer 2 is 800 g / m². 2 The unit area mass of the second flame-retardant needle-punched cotton layer 3 is 200 g / m². 2 Under the same hot-pressing conditions, the hollow heat-insulating microcavity 5 of the resulting composite material has a net height of 1.2 mm, uniform distribution of bonding nodes, and stable structure. When exposed to fire, it can effectively delay the inward conduction of heat.

[0039] The above embodiments show that by controlling the melting point of the PET hot melt adhesive mesh, the hot pressing process parameters, and the geometric parameters of the punch, stable discrete bonding and a controllable hollow heat-insulating microcavity 5 structure can be achieved while ensuring softness and comfort, thus taking into account both dynamic performance and fire safety performance.

[0040] Example 3 An application of a basalt fiber fire-retardant composite material for upholstered furniture is disclosed, in which the composite material is used as a flame-retardant protective layer or flame-retardant padding material in upholstered furniture. The composite material comprises, from top to bottom along its thickness direction, a first flame-retardant needle-punched cotton layer 1, a basalt fiber cloth layer 2, and a second flame-retardant needle-punched cotton layer 3. The first flame-retardant needle-punched cotton layer 1 and the basalt fiber cloth layer 2 are bonded together via discrete hot-melt bonding to form an array of bonding nodes 4, with unbonded areas forming hollow heat-insulating microcavities 5. The basalt fiber cloth layer 2 and the second flame-retardant needle-punched cotton layer 3 are bonded together using a full-area composite method to form a continuous bonding interface. The above structure and its parameter characteristics can be referred to the specific description in Example 1.

[0041] In practical applications, this composite material is cut into corresponding shapes for soft home furnishing components such as sofa cushions, backrests, or armrests, laid on top of the sponge filling and under the fabric, and fixed by sewing or adhesive. For example... Figure 3 In state a, the composite material is in its normal, uncompressed state. When a person sits on or leans against it, the hollow heat-insulating microcavity 5 between the first flame-retardant needle-punched cotton layer 1 and the basalt fiber cloth layer 2 is compressed (e.g., ...). Figure 3 In the middle (b) state, air is expelled from the cavity, the overall thickness decreases, providing a soft and conforming feel; after the pressure is released, relying on the resilience of the needle-punched cotton and the recovery ability of the microcavity structure, air re-enters, and the material returns to its original thickness (e.g., ...). Figure 3 (In the c state). During repeated bending, curling, or compression, the microcavity structure absorbs deformation stress, preventing interlayer separation or wrinkling.

[0042] like Figure 4 As shown, when exposed to fire, the first flame-retardant needle-punched cotton layer 1 initially provides flame retardancy, absorbing heat and delaying the direct penetration of flames. The static air layer within the hollow insulating microcavity 5 effectively slows heat conduction inward due to its low thermal conductivity. The basalt fiber cloth layer 2, acting as a high-temperature resistant skeleton (withstanding 600℃~800℃), is non-combustible and effectively blocks the penetration of flames and high-temperature gases. These three elements work together to form a dynamic air insulation buffer mechanism, significantly delaying heat transfer to the lower filling sponge and delaying heat diffusion to the substrate 6, thus improving fire safety performance. Simulated cigarette smoldering and small flame ignition tests according to GB 20286-2006 showed no ignition of the sponge layer under this application method; the oxygen index test value was ≥30%, meeting the flame retardant level 1 standard.

[0043] The above embodiments are preferred implementations of the present invention. In addition, the present invention can be implemented in other ways. Any obvious substitutions without departing from the concept of the present invention are within the protection scope of the present invention.

Claims

1. A basalt fiber fire-retardant composite material for upholstered home decoration, characterized in that: The basalt fiber fireproof composite material comprises, from top to bottom along the thickness direction, a first flame-retardant needle-punched cotton layer, a basalt fiber cloth layer, and a second flame-retardant needle-punched cotton layer; the first flame-retardant needle-punched cotton layer and the basalt fiber cloth layer are bonded together by discrete hot-melt bonding to form an array of bonding nodes, and the unbonded areas constitute hollow heat-insulating microcavities; the basalt fiber cloth layer and the second flame-retardant needle-punched cotton layer are bonded together by full-area composite or local spot bonding to form a continuous bonding interface.

2. The basalt fiber fire-resistant composite material for upholstered home decoration according to claim 1, characterized in that: The bonding area ratio of the discrete hot melt adhesive is 15%~25%, based on the total area of ​​the first flame-retardant needle-punched cotton layer.

3. The basalt fiber fire-retardant composite material for upholstered home decoration according to claim 1, characterized in that: The hollow thermal insulation microcavity has a net height of 0.5~2.0 mm in the thickness direction.

4. The basalt fiber fire-retardant composite material for upholstered home decoration according to claim 1, characterized in that: The arrayed bonding nodes are arranged in a square matrix, a rectangular matrix, or a rhombus matrix.

5. A basalt fiber fire-retardant composite material for upholstered home decoration according to claim 1, characterized in that: The diameter of the arrayed bonding nodes is 1.5~3.0 mm, and the center-to-center distance between the bonding nodes is 6.0~12.0 mm.

6. The basalt fiber fire-retardant composite material for upholstered home decoration according to claim 1, characterized in that: The unbonded area between the first flame-retardant needle-punched cotton layer and the basalt fiber cloth layer has an out-of-plane convex configuration in the thickness direction, forming a hollow heat-insulating microcavity with closed or semi-closed characteristics.

7. A basalt fiber fire-resistant composite material for upholstered home decoration according to claim 1, characterized in that: The unit area mass of the first flame-retardant needle-punched cotton layer is 60 g / m². 2 ~200 g / m 2 .

8. A basalt fiber fire-resistant composite material for upholstered home decoration according to claim 1, characterized in that: The basalt fiber cloth layer has a unit area mass of 200 g / m³. 2 ~800 g / m 2 .

9. A basalt fiber fire-resistant composite material for upholstered home decoration according to claim 1, characterized in that: The unit area mass of the second flame-retardant needle-punched cotton layer is 60 g / m². 2 ~200 g / m 2 .

10. A basalt fiber fire-retardant composite material for upholstered home decoration according to claim 1, characterized in that: The thickness of the first flame-retardant needle-punched cotton layer is 0.5~5.0 mm.

11. A basalt fiber fire-retardant composite material for upholstered home decoration according to claim 1, characterized in that: The thickness of the basalt fiber cloth layer is 0.2~2 mm.

12. A basalt fiber fire-retardant composite material for upholstered home decoration according to claim 1, characterized in that: The thickness of the second flame-retardant needle-punched cotton layer is 0.5~5.0 mm.

13. A method for preparing a basalt fiber fire-retardant composite material for upholstered home decoration as described in any one of claims 1 to 12, characterized in that: Includes the following steps: S1. Weigh out a unit area mass of 60 g / m². 2 ~200 g / m 2 The first flame-retardant needle-punched cotton layer has a unit area mass of 200g / m². 2 ~800 g / m 2 The basalt fiber cloth layer has a unit area mass of 60 g / m³. 2 ~200 g / m 2 The second flame-retardant needle-punched cotton layer, and a unit area mass of 40 g / m 2 Low-melting-point PET hot melt adhesive mesh; lay the PET hot melt adhesive mesh flat between the first flame-retardant needle-punched cotton layer and the basalt fiber cloth layer, and then stack them neatly in the order of the first flame-retardant needle-punched cotton layer, the basalt fiber cloth layer, and the second flame-retardant needle-punched cotton layer, ensuring that the edges of each layer are aligned and without wrinkles, for later use. S2. Place the stacked material from step S1 between the lower and upper pressing plates of a flat hot press with dot matrix punches for local hot pressing. The punch array applies local pressure in the contact area to melt the low-melting-point PET hot melt adhesive mesh and form discrete bonding nodes after cooling and solidification. S3. Take out the composite material after hot pressing in step S2 and let it cool naturally at room temperature for 4-6 minutes, or use forced convection cooling for 2-3 minutes, so that the PET hot melt adhesive mesh can be completely cured and shaped to form a strong bonding node; finally, cut it according to the required size of the soft home decoration, and check that the bonding nodes are evenly distributed, without delamination or holes, to obtain the finished basalt fiber fireproof composite material.

14. The method for preparing a basalt fiber fire-retardant composite material for upholstered home decoration according to claim 13, characterized in that: In step S1, the melting point of the PET hot melt adhesive mesh is 110~130℃.

15. The method for preparing a basalt fiber fire-retardant composite material for upholstered home decoration according to claim 13, characterized in that: In step S2, the process parameters for the local hot pressing are: hot pressing temperature 130~140℃, hot pressing pressure 0.38~0.42 MPa, and holding time 4 s; During hot pressing, the punch array compacts the first flame-retardant needle-punched cotton layer and the basalt fiber cloth layer at the point contact area. The low-melting-point PET hot melt adhesive mesh melts upon heating and forms a strong bonding node after cooling. The areas not pressed by the punch remain separated, forming a hollow heat-insulating microcavity with a net height of 0.5 mm to 2.0 mm.

16. The method for preparing a basalt fiber fire-resistant composite material for upholstered home decoration according to claim 13, characterized in that: In step S2, the punch unit of the dot matrix punch is a cylindrical boss with a diameter of 3.0 mm, a height of 2.0 mm, a center distance of 6.0 mm, and arranged in a rectangular grid array.

17. The application of the basalt fiber fire-retardant composite material according to any one of 1 to 12 for upholstered home decoration, characterized in that: The basalt fiber fireproof composite material is used as a flame-retardant protective layer or flame-retardant lining material in soft home decoration.

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