Flocking fabric and automotive interior material

Abstract

The utility model provides a flocking fabric which comprises a base cloth layer which is a needle-punched non-woven fabric. The adhesive layer is positioned on the surface of the base cloth layer; the fluff layer is positioned on the surface of the adhesive layer and comprises polyamide fibers; the composite material has the advantages of proper thickness, favorable tear resistance, favorable light fastness, high touch feeling and excellent wear resistance, can be widely applied to automotive interior materials, including but not limited to parts such as ceilings, skylights and door plates, and meets the requirements of subsequent processing, thereby being more suitable for being applied to automotive interiors.

Description

Technical Field

[0001] The utility model relates to the field of fabrics, in particular to a flocked fabric and an automobile interior decoration material. Background Art

[0002] With the progress of the automobile industry, the level of car interior is getting higher and higher. Car interior fabrics usually include flocking fabrics, such as car headliner fabrics, seat cushion fabrics, etc., which have the functions of increasing the beauty of car interiors, refreshing the texture and touch of interiors, and protecting car interiors.

[0003] CN205242165U discloses a mixed flocking fabric, which includes a base fabric and a pile layer fixed on the side of the base fabric, a glue layer is provided between the base fabric and the pile layer, the pile layer is fixed on the side of the base fabric through the glue layer, the glue layer is epoxy resin glue, and the pile layer is a bamboo charcoal fiber part and a viscose pile part arranged at intervals. In the public document, it is claimed that the flocking fabric with good resilience is obtained by using bamboo charcoal fiber and viscose fiber.

[0004] However, the viscose fiber / viscose velvet part itself has low strength, poor abrasion resistance, does not have good tensile properties, and is mostly colored through a post-dyeing process, and has poor light resistance.

[0005] Among the existing flocking fabrics, spunlace non-woven fabrics are mostly used as the base fabric, but the spunlace non-woven fabrics are thin and light in weight. When the flocking fabrics prepared with spunlace non-woven fabrics are used for automotive interior materials, in order to increase the overall feel of the flocking fabrics, it is usually necessary to use them with an additional polyurethane foam layer or a similar thickening layer. In addition, the tensile strength of spunlace non-woven fabrics is relatively low, for example, not higher than 150N / 50mm, and the tear resistance is poor and easy to break. In addition, due to the small thickness of spunlace non-woven fabrics, when used in automotive interiors, in order to meet the overall touch of the interior materials, a supporting layer or a thickening layer, such as polyurethane foam, is usually required, which may cause VOC and odor problems.

[0006] Therefore, how to improve the performance of flocking fabrics so that they can be used in car interiors is an urgent problem that needs to be solved. Utility Model Content

[0007] The problem solved by the utility model is to provide a flocking fabric and an automobile interior material, which has a suitable thickness, good tear resistance, light resistance, high touch, and excellent wear resistance, and can be widely used in the application of automobile interior materials, including but not limited to ceilings, skylights, door panels and other parts, and meets the requirements of subsequent processing, so that it is more suitable for application in automobile interiors.

[0008] In order to solve the above problems, the utility model provides a flocking fabric, comprising: a base fabric layer, which is a needle-punched non-woven fabric; a glue layer located on the surface of the base fabric layer; and a pile layer located on the surface of the glue layer, which is polyamide fiber.

[0009] Optionally, the adhesive layer includes polyurethane adhesive and acrylic adhesive.

[0010] Optionally, the fleece layer comprises PA66 fibers.

[0011] Optionally, the fiber length of the fluff layer is 0.2 mm to 0.7 mm, and / or the fineness of the PA66 fiber is less than 1.5 denier.

[0012] Optionally, the PA66 fiber fineness ranges from 0.7 denier to 1.2 denier.

[0013] Optionally, the weight of the base fabric layer is 100 g to 250 g per square meter, and the thickness of the base fabric layer is 0.8 mm to 2.5 mm.

[0014] Optionally, the thickness of the base fabric layer is 1.0 mm to 2.0 mm.

[0015] Optionally, the tensile strength of the base fabric layer is greater than 250N / 50mm.

[0016] Optionally, a support layer is further included, and the support layer and the adhesive layer are respectively located on opposite surfaces of the base fabric layer.

[0017] Optionally, the supporting layer is a polyurethane foam layer.

[0018] Optionally, the flocked fabric does not include a support layer.

[0019] Optionally, the thickness of the flocking fabric is greater than 2 mm.

[0020] Optionally, a waterproof layer is also included between the base fabric layer and the adhesive layer.

[0021] Correspondingly, the utility model also provides an automobile interior material, comprising the above-mentioned flocking fabric.

[0022] Compared with the prior art, the technical solution of the utility model has the following advantages:

[0023] In the flocking fabric provided by the present technical scheme, the base fabric layer is a needle-punched non-woven fabric, the adhesive layer is located on the surface of the base fabric layer, the fluff layer is located on the surface of the adhesive layer, and the fluff layer includes polyamide fibers. The high strength, high stability, good tensile strength and tear strength properties of the needle-punched non-woven fabric are utilized, and the light resistance of the polyurethane fibers is combined to ensure that the flocking fabric has a suitable thickness and has good tear resistance, light resistance, excellent wear resistance and good touch, which meets the subsequent processing conditions as an automotive interior material, can be widely used in the application of automotive interior materials, and expands the application range of flocking fabrics.

[0024] Furthermore, the fluff layer is PA66 nylon raw silk. Compared with the later dyeing and coloring of viscose fiber, when preparing nylon fiber, additives such as high light-resistant pigments can be added to the PA66 raw material particles to obtain colored nylon fiber, or called colored raw silk. High light-resistant pigments usually cannot be colored through a later dyeing process. This direct coloring reduces the problem of poor light resistance such as fading of flocked fabrics during use, enhances the light resistance of flocked fabrics, and meets the requirements of automotive interiors.

[0025] Furthermore, the material of the base fabric layer is needle-punched non-woven fabric. The fibers of the needle-punched non-woven fabric are placed side by side by needle punching, and then subjected to treatments such as heat pressing and cooling, so that the needle-punched non-woven fabric has higher strength. Therefore, even a thinner base fabric layer can meet the strength of the final flocked fabric. The strength of the flocked fabric can be guaranteed while reducing the thickness of the flocked fabric, so that the flocked fabric can be applied to a wider range of fields.

[0026] Furthermore, when the thickness of the flocking fabric is less than 2 mm, or less than 1.5 mm, the flocking fabric can be used directly, or an additional support layer can be added to further improve the touch and texture of the flocking fabric and expand the application range of the flocking fabric. Preferably, the flocking fabric of the utility model or the interior material containing the flocking fabric of the utility model does not include a support layer. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] Figure 1 It is a structural schematic diagram of the flocking fabric in the utility model. DETAILED DESCRIPTION

[0028] At present, flocking fabrics used in automobile interiors mostly use spunlace non-woven fabrics as the base fabric layer and viscose fiber as the pile layer. The resulting flocking fabrics have shortcomings such as low thickness, low strength, poor light resistance and wear resistance, low tensile properties, and poor stability of the later processing technology; and because they need to be used in combination with a support layer / thickening layer, there are problems with VOC and odor.

[0029] On this basis, the present technical solution proposes a flocking fabric, which uses needle-punched non-woven fabric as the base fabric layer and polyamide fiber as the pile layer, thereby improving the thickness, tensile properties, tear resistance, wear resistance, light resistance, etc. of the flocking fabric, and has a good overall touch and texture without the need to be used in combination with a support layer / thickening layer. Furthermore, the adhesive layer of the present technical solution includes polyurethane adhesive and acrylic adhesive, so that the adhesive layer has the characteristics of high tensile strength and high adhesion at the same time, which not only makes the pile layer of the flocking fabric stable and not easy to fall off, but also makes the flocking fabric have a higher tensile strength, and can be used for subsequent automotive interior processing technology, thereby realizing the application of flocking fabrics to automotive interiors and expanding the application range of flocking fabrics.

[0030] In order to make the above-mentioned objects, features and advantages of the present invention more obvious and understandable, specific embodiments of the present invention are described in detail below with reference to the accompanying drawings.

[0031] First, please refer to Figure 1 A flocking fabric includes a base fabric layer 100 , a glue layer 101 and a flock layer 102 .

[0032] In this embodiment, the base fabric layer is a needle-punched non-woven fabric, which has high strength, so that even a thinner base fabric layer can meet the strength of the final flocking fabric. Combined with the pile layer being a polyamide fiber, the formed flocking fabric not only has a suitable thickness, but also has guaranteed strength, good tear resistance, light resistance, excellent wear resistance and full touch. It can be widely used in automotive interior materials, including but limited to ceilings, skylights, door panels and other parts. The flocking fabric meets the requirements of subsequent processing, and is therefore more suitable for application in automotive interiors.

[0033] In this embodiment, the adhesive layer 101 includes polyurethane adhesive and acrylic adhesive, and also includes other components such as water, penetrant, defoamer, etc.

[0034] In this embodiment, the adhesive layer 101 includes polyurethane adhesive and acrylic adhesive. Not only the high tensile strength of the polyurethane adhesive is used to compensate for the low tensile strength of the acrylic adhesive, but also the high bonding strength of the acrylic adhesive is used to compensate for the low bonding strength of the polyurethane adhesive. As a result, the adhesive layer 101 has not only high tensile strength but also high bonding strength. Then, the flocked fabric formed by using the adhesive layer 101 between the base fabric layer 100 and the fluff layer 102 not only has high tensile strength, but also the fluff layer 102 is tightly bonded, and it is not easy to fall off and reduce the user experience. The high tensile strength allows the flocked fabric to maintain a uniform fluff appearance on the surface of the flocked fabric in subsequent interior processing, such as coating and molding, and will not have defects such as pits. The application of flocked fabric in automotive interiors is of far-reaching significance.

[0035] In this embodiment, the fluff layer is PA66 fiber.

[0036] Specifically, the fluff layer 102 is PA66 nylon raw silk. Compared with the later dyeing and coloring of viscose fiber, when preparing nylon fiber, additives such as high light-resistant pigments can be added to the PA66 raw material particles to obtain colored nylon fiber, or called colored raw silk. High light-resistant pigments usually cannot be colored through a later dyeing process. This direct coloring reduces the problem of poor light resistance such as fading of flocked fabrics during use, enhances the light resistance of flocked fabrics, and meets the requirements of automotive interiors.

[0037] Specifically, PA66 pellets are added with required pigments, such as highly light-resistant pigments, and then spun to obtain colored PA66 nylon raw yarns.

[0038] In this embodiment, the fiber length of the fluff layer 102 is 0.2mm~0.7mm. When the fiber length of the fluff layer 102 is less than 0.2mm, the fiber length of the fluff layer 102 is too short, the difficulty of processing increases, and the quality of the flocking fabric cannot be effectively guaranteed; when the fiber length of the fluff layer 102 is greater than 0.7mm, the fibers of the fluff layer 102 are too long, which may lead to pilling, deformation of the flocking fabric, and shedding of the fluff layer 102.

[0039] Preferably, the fiber length of the pile layer is 0.3-0.5 mm, for example 0.4 mm. Fibers of this length can ensure the quality of flocking while avoiding problems such as shedding, pilling, and deformation, thereby ensuring the high quality of the flocking fabric.

[0040] In this embodiment, the fineness of PA66 fiber is less than 1.5 denier. The finer PA66 fiber can produce a more delicate flocking effect and improve the tactile saturation of the flocking fabric. Therefore, when applied to car interiors, it can ensure the high tactile feel of the flocking fabric and enhance the user experience.

[0041] Preferably, the PA66 fiber fineness ranges from 0.5 denier to 1.5 denier or the PA66 fiber fineness ranges from 0.7 denier to 1.2 denier.

[0042] In this embodiment, the material of the base fabric layer 100 is needle-punched non-woven fabric. The needle-punched non-woven fabric utilizes needle-punching technology to put fibers side by side, and then undergoes treatments such as heat pressing and cooling. This process makes the formed needle-punched non-woven fabric have higher strength, so that even a thinner base fabric layer 100 can meet the strength of the final flocked fabric. The strength of the flocked fabric can be guaranteed while reducing the thickness of the flocked fabric, so that the flocked fabric can be applied to a wider range of fields.

[0043] In this embodiment, the formation process of the base fabric layer 100 includes: providing raw materials, generally short fibers; combing the raw materials after obtaining them; laying the net after combing and waiting to start the machine for needling; turning on the machine for needling, generally starting with pre-needling, the purpose of pre-needling is to preliminarily fix and strengthen the fibers for subsequent processing, and after pre-needling, main needling is formed, and the main needling is to make the fibers more firm and strengthened; after needling, shaping, gluing, drying and rewinding are formed.

[0044] In this embodiment, the weight of the base fabric layer 100 is 100 g to 250 g per square meter, and the thickness of the base fabric layer 100 is 0.8 mm to 2.5 mm.

[0045] In this embodiment, the weight of the base fabric layer 100 is 100g to 250g per square meter. When the weight of the base fabric layer 100 per square meter is less than 100g, the base fabric layer 100 is too thin, and the tensile performance and other properties will be reduced, thereby reducing the service life of the flocking fabric; when the weight of the base fabric layer 100 per square meter is greater than 250g, the base fabric layer 100 is too thick, resulting in the flocking fabric being too thick. The thickness of the flocking fabric will result in poor air permeability, which is not conducive to the dissipation of some odors and reduces the user experience.

[0046] In this embodiment, when the thickness of the base fabric layer 100 is less than 0.8 mm, the thickness of the base fabric layer 100 is too thin, and the strength of the base fabric layer 100 will be reduced, resulting in the flocking fabric being too thin, making the flocking fabric feel poor, and having reduced softness and strength; when the thickness of the base fabric layer 100 is greater than 2.5 mm, the thickness of the base fabric layer 100 is too thick, and the thickness of the flocking fabric is also too thick. Although the thicker the flocking fabric, the more its strength and softness will be guaranteed, but too thick will not have a prominent improvement on the strength and softness, which will easily cause material waste.

[0047] In this embodiment, the tensile strength of the base fabric layer 100 is greater than 250N / 50mm, and the tensile strength of the base fabric layer 100 ensures the tensile strength of the flocking fabric.

[0048] In this embodiment, the thickness of the base fabric layer 100 is 0.8 mm to 2.5 mm, and the tensile strength of the base fabric layer 100 is greater than 250 N / 50 mm, thereby achieving the formation of flocking fabric with low thickness and high tensile strength to meet the requirements of automobile interior processing.

[0049] In this embodiment, the flocked fabric does not include a supporting layer.

[0050] In this embodiment, the thickness of the flocking fabric is greater than 2 mm.

[0051] In this embodiment, a support layer is further included. The support layer and the adhesive layer 101 are respectively located on opposite surfaces of the base fabric layer 100 .

[0052] Specifically, for example, flocking fabric with a thickness of 1.5 mm can be used directly, or a supporting layer can be used to provide texture.

[0053] In this embodiment, the support layer is laminated to the base fabric layer 100 .

[0054] In this embodiment, the support layer is a polyurethane foam layer. Specifically, the support layer can be made of sponge.

[0055] In this embodiment, the different thicknesses of the flocked fabrics can be used to provide users with options for the support layer, thereby expanding the application market of the flocked fabrics.

[0056] In this embodiment, a waterproof layer is further included between the base fabric layer 100 and the adhesive layer.

[0057] In this embodiment, the flocking process of the fluff layer 102 includes: coating the adhesive layer 101 on the base fabric layer 100, putting the prepared polyamide fiber into the flocking equipment, performing flocking on the base fabric layer 100, so that the fluff is fully in contact with the adhesive layer 101 and fixed on the base fabric layer 100, completing the implantation of the fluff, and then performing drying and curing treatment so that the fluff layer 102 and the base fabric layer 100 can be firmly combined, and then performing trimming and finishing as needed, such as brushing, etc., and then rewinding. The flocking process can use known electrostatic flocking processes and equipment.

[0058] The flocking fabric of the utility model can be used for automobile interior materials. When the parts used in the automobile require a relatively thin thickness, the flocking fabric can be used directly. When the parts used in the automobile require a high thickness, thick flocking fabric can be used or thin flocking fabric can be used in combination with a foaming layer.

[0059] In the present application, different base fabric layers, adhesive layers, and pile layers are used to prepare flocking fabric sample 1, sample 2, and a comparative sample. Sample 1 and sample 2 adopt the technical solution of the present utility model.

[0060] The flocking fabric of sample 1 uses a needle-punched non-woven fabric with a thickness of 1mm and a weight of 160g per square meter as the base fabric layer, a glue layer including polyurethane glue and acrylic glue, and PA66 fiber as the fluff layer, with a fiber length of 0.4mm and a fiber fineness of 0.8 denier. The PA66 fiber used has the characteristics of full matte and soft and delicate feel.

[0061] The flocking fabric of sample 2 uses a needle-punched non-woven fabric with a thickness of 1.6mm and a weight of 230g per square meter as the base fabric layer, a glue layer including polyurethane glue and acrylic glue, and PA66 fiber as the fluff layer, with a fiber length of 0.4mm and a fiber fineness of 0.8 denier. The PA66 fiber used has the characteristics of full matte and soft and delicate feel.

[0062] The flocking fabric of the comparative sample is a typical structure in the prior art, using a spunlace nonwoven fabric with a thickness of 0.2 mm and a weight of 50 g per square meter as the base fabric layer, an adhesive layer including acrylic adhesive (but not polyurethane adhesive), and viscose fiber as the fluff layer, with a fiber length of 1.2 mm and a fiber fineness of 1.8 denier. Compared with the PA66 fiber used in Samples 1 and 2, the viscose fiber in the comparative sample is not matte and has a relatively rough feel.

[0063] The weight, thickness, tensile strength, elongation, tear strength, wear resistance, heat aging resistance, wet heat aging resistance, dirt friction test, and light resistance test of the prepared flocking fabric sample 1, sample 2, and the comparison sample were tested. The test results are shown in Table 1 below.

[0064] In this embodiment, the tensile strength and elongation tests were measured according to GB / T 3923.1-2013, and the tear strength was measured according to GB-T 3917.3-2009.

[0065] As can be seen from Table 1, compared with the comparative sample using thin base cloth and long fibers and the sample 1 of the present technical solution using thick base cloth and short fibers, when the thickness of the obtained flocking fabric is equivalent, the flocking fabric sample 1 of the present technical solution has far superior tensile strength (about 2 times) and tear strength (about 7 times) of the comparative sample, and has better wear resistance and light resistance, which can be widely used in the application of automotive interior materials and meet the requirements of subsequent processing, so it is more suitable for application in automotive interiors. In addition, the sample 2 using the present technical solution can obtain a thickness of more than 2mm. At this time, when it is applied to automotive interior materials, there is no need to use a supporting layer / thickening layer such as polyurethane foam, which can reduce VOC and odor problems, which is particularly important in the application of automotive interior materials.

[0066] Table 1: Flocking fabric performance test results

[0067]

[0068] Although the utility model is disclosed as above, the utility model is not limited thereto. Any person skilled in the art can make various changes and modifications without departing from the spirit and scope of the utility model. Therefore, the protection scope of the utility model shall be subject to the scope defined by the claims.

Claims

1. A flocking fabric, characterized in that: include: A base fabric layer, wherein the base fabric layer is a needle-punched nonwoven fabric; A rubber layer located on the surface of the base fabric layer; The fluff layer is located on the surface of the adhesive layer, and the fluff layer includes polyamide fibers.

2. The flocking fabric according to claim 1, characterized in that: The adhesive layer includes polyurethane adhesive and acrylate adhesive.

3. The flocking fabric according to claim 1, characterized in that: The fluff layer includes PA66 fibers.

4. The flocking fabric according to claim 3, characterized in that: The PA66 fiber has a length of 0.2 mm to 0.7 mm, and / or a fineness of less than 1.5 denier.

5. The flocking fabric according to claim 4, characterized in that: The PA66 fiber fineness ranges from 0.7 denier to 1.2 denier.

6. The flocking fabric according to claim 1, characterized in that: The weight of the base fabric layer is 100 g to 250 g per square meter, and the thickness of the base fabric layer is 0.8 mm to 2.5 mm.

7. The flocking fabric according to claim 6, characterized in that: The thickness of the base fabric layer is 1.0 mm to 2.0 mm.

8. The flocking fabric according to claim 1, characterized in that: The tensile strength of the base fabric layer is greater than 250N / 50mm.

9. The flocking fabric according to claim 1, characterized in that: It also includes a supporting layer, wherein the supporting layer and the adhesive layer are respectively located on opposite surfaces of the base fabric layer.

10. The flocking fabric according to claim 9, characterized in that: The supporting layer is a polyurethane foam layer.

11. The flocking fabric according to claim 1, characterized in that: The flocked fabric does not include a supporting layer.

12. The flocking fabric according to claim 11, characterized in that: The thickness of the flocking fabric is above 2 mm.

13. The flocking fabric according to claim 1, characterized in that: It also includes a waterproof layer located between the base fabric layer and the adhesive layer.

14. An automobile interior material, characterized in that: It comprises the flocking fabric as described in any one of claims 1 to 13.

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