Low-density flame-retardant sponge

Abstract

The utility model relates to the technical field of flame-retardant sponges, in particular to a low-density flame-retardant sponge, which comprises a sponge body, the sponge body comprises a central layer, base layers, waterproof layers, buffer layers and wear-resistant layers, the base layers are respectively adhered and fixed on two sides of the central layer through adhesive layers, the waterproof layers are adhered on the other sides of the base layers through adhesive layers, and the buffer layers are arranged on the waterproof layers. A buffer layer is adhered to the other side of the waterproof layer through an adhesive layer, and a wear-resistant layer is adhered to the other side of the buffer layer through an adhesive layer. According to the scheme, through the multi-layer composite structure design, the comprehensive performance is remarkably improved, the center layer is of a glass fiber warp and weft interweaving structure, the tensile strength is enhanced, the base layer is made of a low-density flame-retardant sponge material, the micropore structure design is combined, the light weight, heat insulation and sound absorption functions are achieved, and the waterproof layer and the wear-resistant layer are made of a polyethylene film and a polyvinyl chloride film respectively; water and friction damage are effectively isolated, the shock resistance is further optimized through corrugated protrusions of the buffer layer, all the layers are stably bonded through epoxy resin glue, and it is ensured that the structure is firm.

Description

Technical Field

[0001] This utility model relates to the field of flame-retardant sponge technology, and in particular to a low-density flame-retardant sponge. Background Technology

[0002] Low-density flame-retardant foam is a low-density foam material with flame-retardant properties. This material is commonly used in the manufacture of fire-resistant furniture, building sound insulation materials, automotive interiors, and other applications requiring fire resistance.

[0003] Low density means lighter material weight, making it more flexible and easier to handle in applications. Low-density sponges typically have good flexibility and comfort. Low-density flame-retardant sponges are a type of material with excellent fire resistance and versatility, widely used in various applications requiring both fire protection and comfort. For example, Chinese Patent Publication No. CN213413196U provides a flame-retardant sponge comprising a sponge layer, a partition layer, and a flame-retardant layer. The sponge layer is located on the upper and lower sides of the flame-retardant layer, and the partition layer is located between the sponge layer and the flame-retardant layer. A strip-shaped box is embedded between the flame-retardant layers, and each end of the strip-shaped box has a receiving box that communicates with the interior of the strip-shaped box. A paraffin wax partition is provided at the connection between the receiving box and the strip-shaped box. The two receiving boxes are respectively filled with an aqueous solution of aluminum sulfate and an aqueous solution of sodium bicarbonate. This type of flame-retardant sponge, by setting a strip-shaped box and a containment box inside the flame-retardant layer, allows the paraffin on the paraffin partition to melt when the temperature rises, while the holes on the partition are exposed. This allows the aluminum sulfate aqueous solution and sodium bicarbonate aqueous solution filled in the containment box to mix with the strip-shaped box, generating carbon dioxide gas, and producing foam through a foaming agent, thus achieving a flame-retardant and fire-extinguishing effect.

[0004] Currently, most sponge structures are used in building sound insulation and interior decoration. While a simple sponge structure can provide some sound insulation and cushioning, it is easily damaged by moisture and wear over long-term use. Therefore, a protective structure needs to be designed to improve the durability and lifespan of the sponge. Utility Model Content

[0005] The purpose of this invention is to address the aforementioned shortcomings in the existing technology by proposing a low-density flame-retardant sponge.

[0006] To achieve the above objectives, the present invention adopts the following technical solution:

[0007] Design a low-density flame-retardant sponge, including a sponge body, the sponge body comprising a central layer, a base layer, a waterproof layer, a buffer layer, and a wear-resistant layer, the base layer being bonded to both sides of the central layer by adhesive layers, the waterproof layer being bonded to the other side of the base layer by adhesive layers, the buffer layer being bonded to the other side of the waterproof layer by adhesive layers, and the wear-resistant layer being bonded to the other side of the buffer layer by adhesive layers.

[0008] The central layer comprises meridians and parallels, which are interwoven and fixed together.

[0009] The surface of the base layer has several through holes;

[0010] The surface of the buffer layer is provided with corrugated protrusions.

[0011] In detail, both the warp and weft threads are made of glass fiber material.

[0012] In detail, the base layer is made of low-density flame-retardant sponge material.

[0013] In detail, the waterproof layer is made of polyethylene film material.

[0014] In detail, the buffer layer is made of rubber material.

[0015] In detail, the wear-resistant layer is made of polyvinyl chloride film material.

[0016] In detail, the adhesive layer is made of epoxy resin adhesive material.

[0017] The design scheme proposed in this utility model has the following beneficial effects in application:

[0018] 1. This solution significantly improves overall performance through a multi-layer composite structure design. The core layer uses a fiberglass weft-woven structure to enhance tensile strength. The base layer uses low-density flame-retardant sponge material with a microporous structure design, which combines lightweight, heat insulation and sound absorption functions. The waterproof layer and wear-resistant layer use polyethylene film and polyvinyl chloride film respectively to effectively isolate moisture and friction damage. The corrugated protrusions of the buffer layer further optimize the impact resistance. All layers are stably bonded with epoxy resin to ensure a solid structure. This design achieves multiple effects of flame retardancy, waterproofing, buffering and wear resistance while ensuring low density, and is suitable for scenarios with high requirements for safety and durability.

[0019] 2. The base material achieves a balance between low density and high flame retardancy through the scientific formulation of polyurethane, flame retardants, foaming agents, and other components. The addition of phosphate esters or nitrogen-based flame retardants significantly improves fire resistance, while the microporous structure regulated by foaming agents and surfactants reduces weight and enhances heat insulation and sound absorption capabilities. In addition, the synergistic effect of the waterproof layer and wear-resistant layer extends the service life of the material and avoids performance degradation due to moisture or friction. The overall structure is lightweight and fully functional, and can be widely used in automotive interiors, building sound insulation, or home furnishings, meeting the dual requirements of safety, environmental protection, and practicality. Attached Figure Description

[0020] Figure 1 This is a schematic diagram of the overall structure of this utility model;

[0021] Figure 2 This is a schematic diagram of the central layer structure of this utility model;

[0022] Figure 3 This is a schematic diagram of the base structure of this utility model;

[0023] Figure 4 This is a schematic diagram of the buffer layer structure of this utility model.

[0024] In the diagram: 1. Sponge body; 101. Core layer; 102. Base layer; 103. Waterproof layer; 104. Buffer layer; 1011. Warp; 1012. Weft; 1021. Through hole; 1041. Corrugated protrusion. Detailed Implementation

[0025] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present utility model. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments.

[0026] Reference Figures 1-4 A low-density flame-retardant sponge includes a sponge body 1. The sponge body 1 includes a central layer 101, a base layer 102, a waterproof layer 103, a buffer layer 104, and a wear-resistant layer 105. The base layer 102 is bonded to both sides of the central layer 101 by adhesive layers. The waterproof layer 103 is bonded to the other side of the base layer 102 by adhesive layers. The buffer layer 104 is bonded to the other side of the waterproof layer 103 by adhesive layers. The wear-resistant layer 105 is bonded to the other side of the buffer layer 104 by adhesive layers.

[0027] The central layer 101 includes meridians 1011 and parallels 1012, which are interwoven and fixed together.

[0028] The surface of the base layer 102 is provided with several through holes 1021. The through holes 1021 are microporous structures, which can improve the heat insulation and sound absorption of the base layer 102.

[0029] The surface of the buffer layer 104 is provided with corrugated protrusions 1041. The corrugated structure can improve the buffering capacity of the buffer layer 104.

[0030] It should be further noted that both the warp 1011 and the weft 1012 are made of glass fiber material, which can improve the tensile strength of the entire sponge body 1 at the center.

[0031] It should be further explained that the base layer 102 is made of low-density flame-retardant sponge material, specifically composed of polyurethane, flame retardant, foaming agent, catalyst, and surfactant. Polyurethane is a commonly used foam material with good elasticity and comfort. By adjusting the formula and production process, low-density polyurethane foam can be prepared. Flame retardant is the key component that gives the sponge its flame-retardant properties. Common flame retardants include phosphate esters, halogens, and nitrogen-based flame retardants. Foaming agent is used to generate the foam structure during the production process. Common foaming agents include water, carbon dioxide, and nitrogen. Catalyst is used to accelerate the chemical reaction and promote the formation and curing of foam. Common catalysts include amines and tin compounds. Surfactant is used to adjust the pore size and stability of the foam. They can help form a uniform foam structure and improve the quality and performance of the foam.

[0032] It should be further noted that the waterproof layer 103 is made of polyethylene film material, which can provide waterproof protection for the base layer 102 and prevent external moisture from contacting the base layer 102.

[0033] It should be further noted that the buffer layer 104 is made of rubber material, which has toughness and cushioning ability.

[0034] It should be further noted that the wear-resistant layer 105 is made of polyvinyl chloride film material, which can protect against external friction and scratches.

[0035] It should be further noted that the adhesive layer is made of epoxy resin material, which can achieve stable bonding between the layers.

[0036] Working method: This solution achieves efficient flame retardancy and heat insulation through the synergistic effect of multiple materials. The core layer 101 is composed of warp 1011 and weft 1012 woven from glass fiber. The high temperature resistance of glass fiber (melting point exceeding 1000℃) can maintain structural stability in a fire and prevent overall collapse. The base layer 102 uses low-density polyurethane foam. Its flame retardants (such as phosphate esters) decompose to generate a phosphate layer when heated, which isolates oxygen and inhibits the release of combustible gases. At the same time, the microporous structure of the through-pores 1021 reduces heat conduction by trapping air and improves heat insulation performance. The polyethylene film of the waterproof layer 103 further blocks external moisture penetration and avoids moisture from reducing the activity of flame retardants. When external high temperature or flame attack, the polyvinyl chloride film of the wear-resistant layer 105 first carbonizes to form a protective layer, and the rubber material of the buffer layer 104 slows down heat transfer. Finally, a gradient protection system from the outside to the inside is formed to achieve the dual goals of flame retardancy and heat insulation.

[0037] The corrugated protrusions 1041 of the buffer layer 104 are key to its core buffering function. When an external impact force is applied to the wear-resistant layer 105, the rigid surface of the PVC film first disperses part of the pressure, and then the force is transmitted to the rubber buffer layer 104. The corrugated structure transforms the concentrated stress into a multi-directional dispersed force through elastic deformation, prolonging the impact time. At the same time, the low-density sponge of the base layer 102 absorbs the remaining energy through microporous collapse, similar to the principle of "honeycomb energy absorption". The glass fiber mesh of the central layer 101 provides tensile support to prevent interlayer tearing.

[0038] The above description is only a preferred embodiment of the present utility model, but the protection scope of the present utility model is not limited thereto. Any equivalent substitutions or changes made by those skilled in the art within the technical scope disclosed in the present utility model, based on the technical solution and the inventive concept of the present utility model, should be included within the protection scope of the present utility model.

Claims

1. A low density flame retardant sponge comprising a sponge body (1), characterized in that: The sponge body (1) includes a central layer (101), a base layer (102), a waterproof layer (103), a buffer layer (104), and a wear-resistant layer (105). The base layer (102) is bonded to both sides of the central layer (101) by adhesive layers. The waterproof layer (103) is bonded to the other side of the base layer (102) by adhesive layers. The buffer layer (104) is bonded to the other side of the waterproof layer (103) by adhesive layers. The wear-resistant layer (105) is bonded to the other side of the buffer layer (104) by adhesive layers. The central layer (101) includes meridians (1011) and parallels (1012), which are interwoven and fixed together. The surface of the base layer (102) is provided with a plurality of through holes (1021); The surface of the buffer layer (104) is provided with corrugated protrusions (1041).

2. A low density, flame retardant sponge according to claim 1, wherein: Both the warp (1011) and weft (1012) are made of glass fiber material.

3. A low density, flame retardant foam according to claim 1 wherein: The base layer (102) is made of low-density flame-retardant sponge material.

4. A low density, flame retardant foam according to claim 1 wherein: The waterproof layer (103) is made of polyethylene film material.

5. A low density, flame retardant foam according to claim 1 wherein: The buffer layer (104) is made of rubber material.

6. A low density, flame retardant foam according to claim 1 wherein: The wear-resistant layer (105) is made of polyvinyl chloride film material.

7. A low density, flame retardant foam according to claim 1 wherein: The adhesive layer is made of epoxy resin adhesive material.

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