Three-dimensional loop material, its manufacturing method and its use

Abstract

A three-dimensional loop material comprising loop fibers of polyethylene or ethylene / α-olefin elastomer coated with at least one flame retardant is provided in this disclosure. The loop fibers contain 0.5% to 40% by weight of the flame retardant, based on the total weight of the loop fibers. The three-dimensional loop material has desirable flame resistance, particularly for the transportation industry, e.g., for vehicle seat applications. Furthermore, this disclosure provides a method for manufacturing the three-dimensional loop material and the use of the three-dimensional loop material, e.g., vehicle seats manufactured therefrom.

Description

[Technical Field]

[0001] This disclosure relates to three-dimensional loop (3D loop or 3DL) materials made from polyethylene or ethylene / α-olefin elastomer having desirable flame resistance, particularly for the transportation industry, e.g., vehicle seat applications; methods for manufacturing three-dimensional loop materials; and the use of three-dimensional loop materials, e.g., vehicle seats manufactured therefrom. [Background technology]

[0002] Three-dimensional loop (3D loop) materials or pads are molten polymer filaments that form a random network structure, and are made, for example, from polyethylene (PE) or polyolefin (POE). They have proven to be well-suited for use in mattresses, pillows, and the like. Compared to polyurethane (PU) foam, 3D loop materials offer good elasticity, an open structure for high breathability, good durability, and easy cleaning. In addition, the thermoplastic properties of 3D loop materials make them highly recyclable, significantly contributing to the reduction of plastic waste compared to PU foam. Based on these advantageous properties, 3D loop materials have great potential in the transportation industry, for example, in vehicle seat applications.

[0003] In the transportation sector, seats are used in compact spaces and may be for public purposes. Flame resistance requirements are stricter than for household use. For example, car seat cushions should meet the flammability standards for automotive interior materials. However, neat polyethylene or polyolefin 3D loop materials can hardly achieve such high flame resistance from both a material and structural standpoint. As a result, current polyethylene or polyolefin 3D loop materials cannot be applied to the automotive seat industry.

[0004] The incorporation of flame retardants (FRs) is an effective strategy for improving flame resistance, and the use of halogen-free flame retardants is preferable. However, halogen-free flame retardants have low compatibility with the POE / PE matrix, so it is necessary to ensure good flame resistance, and such high filling inevitably affects the mechanical properties of the 3D loop material, such as resilience and durability.

[0005] Therefore, the need for highly efficient flame-retardant polyethylene or polyolefin formulations to produce 3D loop materials that offer a good balance between flame resistance and mechanical properties remains unmet in the transportation industry, particularly for vehicle seat applications. [Overview of the Initiative]

[0006] As a result of diligent research, the inventors have surprisingly developed a three-dimensional loop material that exhibits an excellent horizontal combustion rate of less than 100 mm / min and a good flexural modulus of less than 100 MPa.

[0007] In one embodiment, the disclosure provides a three-dimensional loop material comprising loop fibers of polyethylene or ethylene / α-olefin elastomer coated with at least one flame retardant, wherein the loop fibers contain 0.5% to 40% by weight of the flame retardant based on the total weight of the loop fibers.

[0008] In a further embodiment, the present disclosure provides a method for manufacturing a three-dimensional loop material, the method is (i) A step of providing polyethylene or ethylene / α-olefin elastomer loop fibers, (ii) A step of coating the loop fibers with at least one flame retardant and an optional binder.

[0009] In a further embodiment, the disclosure provides a vehicle seat comprising a three-dimensional loop material.

[0010] It should be understood that both the foregoing general description and the following detailed description are merely exemplary and explanatory, and do not limit the claimed invention.

Brief Description of Drawings

[0011] [Figure 1] (From left to right) shows the screw design of ZSK18 for preparing a flame - resistant POE composition according to an embodiment of the present disclosure. [Figure 2] Shows the durability test for FR coating test pieces and sampling according to an embodiment of the present disclosure.

Modes for Carrying Out the Invention

[0012] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the technical field to which this invention belongs. Also, all publications, patent applications, patents, and other references mentioned herein are incorporated by reference.

[0013] I. Definitions All percentages referred to herein are by weight, and temperatures are in °C unless otherwise stated, not implied by the context, or not customary in the art.

[0014] The term "and / or" means "and, or alternatively". All ranges include their endpoints unless otherwise indicated.

[0015] The terms "comprising", "including", "having", and their derivatives, as used herein, are not intended to exclude the presence of any additional components, steps, or procedures, whether or not specifically disclosed. To avoid any ambiguity, all compositions claimed through the use of the term "comprising" may include any additional additives, adjuvants, or compounds, whether polymeric or not, unless the contrary is stated. In contrast, the term "consisting essentially of" excludes any other components, steps, or procedures from the scope of any preamble, except for those that are essential to the practicability. The term "consisting of" excludes any component, step, or procedure not specifically depicted or listed.

[0016] A "composition" or "formulation" is a mixture or blend of two or more components. In the context of a mixture or blend of materials from which a manufactured article is made, the composition includes all components of the mixture, such as polymers, flame retardants, and antioxidants, and any other additives or agents, such as dyes.

[0017] A "polymer" is a polymeric compound prepared by polymerizing monomers, whether of the same type or different types. Thus, the general term "polymer" encompasses the term "homopolymer", which is usually used to refer to a polymer prepared from only one type of monomer, and the term "interpolymer".

[0018] An "interpolymer" is a polymer prepared by polymerizing two or more different types of monomers. This general term includes copolymers, which are usually used to refer to polymers prepared from two different types of monomers and polymers prepared from three or more different types of monomers, such as terpolymers, tetrapolymers, etc.

[0019] "Alpha-olefin" or "α-olefin" generally refers to a carbon atom containing ethylenically unsaturated carbon between the first and second carbon atoms. 3~20 It is a linear, branched, or cyclic hydrocarbon molecule.

[0020] "Polyolefin" or "POE" is a polymer that contains more than 50 mole percent of polymerizable olefin monomers (based on the total amount of polymerizable monomers) and may optionally contain one or more comonomers. Non-limiting examples of olefin polymers include ethylene polymers and propylene polymers.

[0021] An "ethylene / alpha-olefin interpolymer" is an interpolymer comprising a majority (i.e., more than 50 mole percent) of polymerized ethylene monomers (based on the total amount of polymerizable monomers) and one or more alpha-olefin comonomers.

[0022] The term "flame retardant" is used herein to refer to a flame retardant which may be any halogen-containing compound or mixture of compounds that imparts flame resistance to the compositions or materials of the present disclosure.

[0023] II. Three-dimensional loop materials This disclosure provides a three-dimensional loop material comprising fibers with a random loop structure. In some embodiments, the random loop fibers are bonded to one another, and the loops are formed randomly by bending continuous fibers and bringing them into contact with each other in a molten state, and then thermally fusing them at multiple contact points.

[0024] The majority of the fibers contained in the three-dimensional loop material are manufactured from the polyethylene or ethylene / α-olefin elastomer of the Disclosure, also referred to herein as “polymer fibers.” In some embodiments, based on the total weight of the fibers contained in the three-dimensional loop material, more than 90%, more than 95%, more than 98%, more than 99%, more than 99.5%, or more than 99.9% of the fibers are manufactured from the polyethylene or ethylene / α-olefin elastomer loop fibers of the Disclosure.

[0025] In some embodiments, less than 10%, less than 5%, less than 2%, less than 1%, less than 0.5%, or less than 0.1% of the fibers, based on the total weight of the fibers contained in the three-dimensional loop material, are made from other materials, such as aramid fibers, polyester fibers, or cellulose fibers (e.g., regenerated cellulose fibers). In some embodiments, less than 10%, less than 5%, less than 2%, less than 1%, less than 0.5%, or less than 0.1% of the fibers, based on the total weight of the fibers contained in the three-dimensional loop material, are made from propylene polymers. In some embodiments, the propylene polymer does not contain PBE.

[0026] In some embodiments, the fibers in the three-dimensional loop material have a diameter of about 0.3 mm or more. In some embodiments, the fibers in the three-dimensional loop material have a diameter of about 2.0 mm or less. In some embodiments, the fibers in the three-dimensional loop material have a diameter within a range formed by using any two of the following enumerated values ​​as endpoints: 0.3, 0.4, 0.5, 0.6, 0.8, 1.0, 1.2, 1.4, 1.6, 1.8, 1.9, and 2.0 mm. In some embodiments, the fibers in the three-dimensional loop material have a diameter within the range of about 0.3 mm to about 2.0 mm, about 0.5 mm to about 2.0 mm, about 0.3 mm to about 1.8 mm, or about 0.5 mm to about 1.8 mm.

[0027] In some embodiments, the three-dimensional loop material is approximately 30 kg / m 3 It has a density of approximately 100 kg / m³. In some embodiments, the three-dimensional loop material has a density of approximately 100 kg / m³. 3 It has the following densities. In some embodiments, the three-dimensional loop material has the following enumerated endpoints: 30, 40, 50, 60, 70, 80, 90, and 100 kg / m 3 The density is within a range formed by using any two of the numerical values ​​in the given range. In some embodiments, the three-dimensional loop material has a density of approximately 30 kg / m 3 ~about 100kg / m 3 , about 50kg / m 3~ about 100 kg / m 3 、 about 30 kg / m / m 3 ~ about 80 kg / m 3 、 or about 50 kg / m 3 ~ about 100 kg / m 3 and has a density within the range of.

[0028] In some embodiments, the three - dimensional loop material is a non - woven material.

[0029] In some embodiments, the loop fibers contain 0.5 wt% - 40 wt%, 0.5 wt% - 30 wt%, 0.5 wt% - 20 wt%, 0.5 wt% - 10 wt%, or 0.5 wt% - 5 wt% of a flame retardant based on the total weight of the loop fibers.

[0030] In some embodiments, the loop fibers of polyethylene or ethylene / α - olefin elastomer have a melting index (MI) in the range of 2 - 20 g / 10 min, 4 - 15 g / 10 min, or 6 - 10 g / 10 min.

[0031] In some embodiments, the horizontal burning rate of the three - dimensional loop material is less than 100 mm / min, less than 80 mm / min, less than 60 mm / min, less than 40 mm / min, or less than 20 mm / min.

[0032] In some embodiments, the flexural modulus of the polymer (e.g., polymer fibers, or fibers of polyethylene or ethylene / α - olefin elastomer) contained in the three - dimensional loop material, measured according to ASTM D790, is less than 100 MPa, less than 70 MPa, or less than 30 MPa.

[0033] III. Polyethylene or Ethylene / α - Olefin Elastomer The three - dimensional loop material comprises (a) at least one polyethylene or ethylene / α - olefin, (b) at least one flame retardant, and (c) an optional binder. <00​In some embodiments, at least one flame retardant and an optional binder are coated onto at least one polyethylene or ethylene / α-olefin loop fiber instead of being mixed or blended together (i.e., a blend / filling process).

[0035] In some embodiments, polyethylene or ethylene / α-olefin elastomers have a melting index (MI) in the range of 2 to 20 g / 10 min at 190°C and 2.16 kg, for example, 5 to 20, 8 to 15, or 10 to 15 g / 10 min at 190°C and 2.16 kg, when measured according to ASTM D1238.

[0036] In some embodiments, polyethylene or ethylene / α-olefin elastomer has a melting peak temperature (Tm) of less than 121°C.

[0037] In some embodiments, the polyethylene or ethylene / α-olefin elastomer may further contain one or more additives such as antioxidants, pigments, and compounding aids.

[0038] IV. Ethylene / alpha-olefin copolymer In some embodiments, the ethylene / alpha-olefin copolymer is a random ethylene / alpha-olefin interpolymer or a blocked ethylene / alpha-olefin interpolymer.

[0039] Ethylene / alpha-olefin copolymers contain ethylene as the main monomer. In some embodiments, the ethylene / alpha-olefin copolymer contains at least 60% by weight of the copolymer, for example, at least 65% by weight, at least 70% by weight, at least 75% by weight, or at least 80% by weight of ethylene as the main monomer. In some embodiments, the amount of ethylene contained in the ethylene / alpha-olefin copolymer is within a range formed by using any two of the following values ​​of 60% by weight, 65% by weight, 70% by weight, 75% by weight, 80% by weight, 85% by weight, and 90% by weight of the copolymer as endpoints. In some embodiments, the ethylene / alpha-olefin copolymer contains 60% to 90% by weight, 65% to 90% by weight, 70% to 90% by weight, or 75% to 90% by weight of ethylene.

[0040] Ethylene / alpha-olefin copolymers contain at least one alpha-olefin as a comonomer. Typically, the at least one alpha-olefin contained in the ethylene / alpha-olefin copolymers of this disclosure has four or more carbon atoms. In some embodiments, the ethylene / alpha-olefin copolymer contains one or more C as a comonomer. 4~10 Contains alpha-olefin. In some exemplary embodiments, C 4~10 The alpha-olefin can be selected from the group consisting of 1-butene, 1-pentene, 1-hexene, 1-heptene, 1-octene, 1-nonene, 1-decene, and combinations thereof. In some embodiments, C 4~10 The alpha-olefin contains 1-octene. In some exemplary embodiments, the ethylene / alpha-olefin copolymer can be selected from the group consisting of ethylene / 1-hexene copolymer, ethylene / 1-heptene copolymer, ethylene / 1-octene copolymer, ethylene / 1-nonene copolymer, ethylene / 1-decene copolymer, and combinations thereof. In embodiments, the ethylene / alpha-olefin copolymer contains ethylene / 1-octene copolymer.

[0041] In some embodiments, the ethylene / alpha-olefin copolymer is present in a copolymer of up to 40% by weight, for example, up to 35% by weight, up to 30% by weight, up to 25% by weight, up to 20% by weight, up to 15% by weight, or up to 10% by weight of C 4~10 It contains alpha-olefin as a comonomer. In some embodiments, the ethylene / alpha-olefin copolymer contains C 4~10 The amount of alpha-olefin is within the range formed by using any two of the following values ​​of the copolymer as endpoints: 40% by weight, 35% by weight, 30% by weight, 25% by weight, 20% by weight, 15% by weight, and 10% by weight. In some embodiments, the ethylene / alpha-olefin copolymer is 40% to 10% by weight, 35% to 10% by weight, 30% to 10% by weight, or 25% to 10% by weight of C in the copolymer. 4~10 Contains alpha-olefin.

[0042] Examples of ethylene / alpha-olefin copolymers suitable for use in this disclosure include those marketed by The Dow Chemical Company under the trade name ENGAGE®.

[0043] V. Flame retardants At least one type of flame retardant is coated onto the loop fibers, enabling them to be extinguished or at least slowing the spread of fire in the material, and suitable use in the transportation industry can be found.

[0044] In some embodiments, at least one flame retardant is selected from halogen-containing flame retardants or halogen-free flame retardants. In some embodiments, the flame retardant includes halogen-free flame retardants. In some embodiments, at least one flame retardant is selected from phosphates, phosphonates, and combinations thereof.

[0045] In some specific embodiments, at least one flame retardant is selected from cyclic phosphonates, triaryl phosphates, cresyl diphenyl phosphates, tricresyl phosphates, trixylyl phosphates, triethyl phosphates, isodecyl diphenyl phosphates, oligomeric phosphate-phosphonates, cyclic organophosphates and phosphonates, and nitrogen-containing polyol phosphates.

[0046] Optionally, other known flame retardants, such as metal hydroxides, can be additionally coated onto the loop fibers.

[0047] In some embodiments, flame retardant synergies can be used to enhance the effectiveness of the flame retardant. Flame retardant synergies include inorganic and organic flame retardant synergies. Examples of inorganic flame retardant synergies include, but are not limited to, metal oxides such as iron oxide, tin oxide, zinc oxide, aluminum oxide, alumina, antimony oxide and antimony oxide, bismuth oxide, molybdenum trioxide, and tungsten trioxide, boron compounds such as zinc borate, zinc stannate, zinc hydroxystannate, ferrocene, and mixtures thereof. Examples of organic flame retardant synergies include, but are not limited to, organic peroxides such as dicumyl peroxide and polycumyl peroxide. A non-limiting example of a flame retardant synergy is antimony oxide (CAS number 1309-64-4).

[0048] In some embodiments, the flame retardant synergist can be coated onto the loop fibers in amounts of 0.3% to 3% by weight, 0.5% to 2.5% by weight, 0.5% to 2% by weight, 0.5% to 1.5% by weight, or 0.7% to 1.2% by weight.

[0049] In some embodiments, halogen-free flame retardants and flame retardant synergies are used in weight ratios of 0.25:1 to 15:1, for example, within a range defined by using any two of the following values ​​as endpoints: 0.5:1, 0.8:1, 1:1, 1.5:1, 1.8:1, 2:1, 2.5:1, 3:1, 3.5:1, 4:1, 4.5:1, 5:1, 6:1, 7:1, 8:1, 9:1, 10:1, 11:1, 12:1, 13:1, 14:1, and 15:1. In some embodiments, halogen-free flame retardants and flame retardant synergies are used in weight ratios of 0.25:1 to 10:1, 0.5:1 to 5:1, 1:1 to 5:1, 2:1 to 4:1, or approximately 3:1.

[0050] In some embodiments, the total amount of flame retardant and flame retardant synergistic agent filling in the three-dimensional loop material is 5% by weight or less of the material, for example, 4.5% by weight, 4% by weight, 3.5% by weight, or 3% by weight or less of the material.

[0051] In some embodiments, the polyethylene or ethylene / cresyldiphenyl phosphate loop fibers contain 0.3% to 3% by weight of an expandable flame retardant, based on the weight of the loop fibers, the expandable flame retardant being selected from the group consisting of ammonium polyphosphate, polymeric piperazine pyrophosphate, melamine phosphate, and expandable blends.

[0052] In this invention, examples of flame retardants include those commercially available under the trade names FR-8201, R-8051, FR-8038, and FR-8031 from ZhongKang Guochuang Advanced Technology Research Institute of Dyeing and Finishing Co., those commercially available under the trade name Antiblaze CU from Hangzhou Electrochemical Group Co. Ltd., and those commercially available under the trade names Pekoflam PES, Aflammit PE Conc, and PCO 900 from Archroma (formerly Clariant), which are cyclic phosphonates:

[0053] [ka] It contains.

[0054] Furthermore, as a flame retardant, for example, there is a product containing piperazine pyrophosphate (PPAP) that is commercially available from ADEKA under the trade name FP-2500S.

[0055] An example of a flame retardant is available from Hangzhou Jiersi under the trade name JIL-PNA220-A, and contains ammonium polyphosphate (APP), among other ingredients.

[0056] VI. Binder In the present invention, loop fibers are coated with a mixture of at least one flame retardant and a binder, wherein the weight ratio of halogen-free flame retardant to binder is 1:(0.05~5), 1:(0.05~4), 1:(0.05~3), 1:(0.05~2), 1:(0.05~1), 1:(0.05~0.5), or 1:(0.05~0.1). Various binders can be used to stabilize the three-dimensional loop material. The term “binder” as used herein refers to the material within the 3D loop material (other than the loop fibers) that fixes the loop fibers. In some embodiments, the binder is an adhesive. The binder preferably penetrates and infiltrates completely into the gaps between individual loop fibers in the entanglement of the 3D loop material. When a liquid binder is used, the binder is preferably selected to have a sufficiently low viscosity and surface tension to allow it to flow into the untightened (or tightened) entanglement. In embodiments where the entanglement is tightened later (such as loop materials), this selected distribution of the fluid binder helps to secure the associated knots with minimal hardening of the entire product, without requiring a significant amount of binder.

[0057] In any case, the amount and penetration of the binder should be selected to adequately stabilize the loop material and secure the loops so that they are not pulled out of their associated entanglement, while avoiding substantial interference with the desired hook-engagement function of the loop fibers. For use in applications where the loop material may come into direct contact with sensitive skin, such as vehicle seats, the amount and type of binder should be selected to be biocompatible to avoid skin irritation. For example, a formaldehyde-free binder is preferred. Since irritation can be exacerbated by rigidity, preferably, only enough binder to perform the above functions is applied. In some applications, such as those where the loop material is directly bonded to a supporting fabric and substantial fastener strength is not required, the loop product may be supplied without a binder.

[0058] In some embodiments, the binder may include, but is not limited to, olefin(co)polymers, (meth)acrylic(co)polymers, acrylate-based emulsion copolymers, and polyurethane resins. A preferred binder used in the present disclosure is formulation (B), which may be an aqueous dispersion comprising at least one olefin(co)polymer and at least one olefin-(meth)acrylic copolymer. The olefin(co)polymer may be C2-C 16 Alkene homopolymers, two or more C2-C2 16 Alkene copolymers, or at least one C2-C 16 It may be a copolymer of an alkene and at least one vinyl comonomer other than an olefin. The olefin (co)polymer may have a melt flow rate (MFR) in the range of 0.1 to 50 g / 10 min, as measured according to ASTM D-1238 (190°C / 2.16 kg). The olefin (co)polymer content may be 10 to 50% by weight based on the total weight of the dispersion. The olefin-(meth)acrylic copolymer may be at least one C2-C 16It may be a copolymer of an alkene and at least one (meth)acrylic monomer. The (meth)acrylic monomer is methacrylic acid, acrylic acid, methacrylamide, acrylamide, methacrylonitrile, acrylonitrile, (C1-C 12 )Alkyl methacrylates (e.g., methyl methacrylate, ethyl methacrylate, propyl methacrylate, butyl methacrylate, pentyl methacrylate, hexyl methacrylate, etc.), (C1~C 12 The copolymer may contain alkyl acrylates (e.g., methyl acrylate, ethyl acrylate, propyl acrylate, butyl acrylate, pentyl acrylate, hexyl acrylate, etc.) and any combination thereof. The olefin-(meth)acrylic copolymer may have a melt flow rate (MFR) in the range of 0.1 to 50 g / 10 min, as measured according to ASTM D-1238 (190°C / 2.16 kg). The content of the olefin-(meth)acrylic copolymer may be 2 to 30% by weight, based on the total weight of the dispersion.

[0059] A preferred binder used in this disclosure may be an acrylate emulsion copolymer. The acrylate emulsion copolymer has a Tg in the range of -40°C to 15°C. The pH of the acrylate emulsion copolymer is in the range of 6.0 to 8.5. The solids content is 25% to 50%. The copolymer in the acrylate emulsion copolymer may contain copolymerizable acrylate monomers having a Tg range of -20°C to -80°C, and examples of acrylate monomers include, but are not limited to, 2-ethylhexyl acrylate, butyl acrylate, ethyl acrylate, and combinations thereof. The copolymer in the acrylate emulsion copolymer may contain copolymerizable monomers having a Tg range of 20°C to 200°C, and examples of monomers include, but are not limited to, methyl methacrylate, styrene, vinyl acetate, acrylic acid, methacrylic acid, and combinations thereof.

[0060] A suitable binder used in this disclosure may be an aqueous dispersion of polyurethane resin. The binder may contain one or more conventional additives such as surfactants, emulsifiers, fillers, film-forming agents, colorants, pigments, thickeners, migration inhibitors, curing agents, film-forming aids, biocides, plasticizers, waxes, anti-aging agents, or antioxidants. In addition to the above components, the binder may also contain the remaining amount of water, such as having a water content of about 30% to 75% by weight.

[0061] In this disclosure, exemplary binders include those marketed by The Dow Chemical Company under the trade names PRIMAL ST-954, PRIMAL® TR-3349, PRIMAL® ECO-1291, Hypol 8501, Lucidene 606 APEF, PRIMAL NPC64A, and PUB.

[0062] VII. Manufacturing of Three-Dimensional Loop Materials This disclosure also provides a method for manufacturing the three-dimensional loop material disclosed herein, the method is (i) A step of providing polyethylene or ethylene / α-olefin elastomer loop fibers, (ii) A step of coating the loop fibers with at least one flame retardant and an optional binder.

[0063] As used herein, the term “coating” includes, but is not limited to, exposing loop fibers or 3D loop material to a flame retardant and an optional binder, and includes spray coating, immersion, dip coating, and the like. In some embodiments, loop fibers may be coated before and / or after forming a 3D loop material. Unlike blending or filling processes used in the prior art, the coating process of this disclosure can reduce the amount of flame retardant filled to a maximum of 10% by weight of the loop fibers while maintaining the desired flame resistance, e.g., a horizontal burning rate of less than 100 mm / min. Blending or filling processes used in the prior art generally require at least 40% by weight of flame retardant filled.

[0064] In further embodiments of this disclosure, the method (a) A step of melting polyethylene or ethylene / α-olefin copolymer and an optional additive to form a molten composition, (b) A step of discharging the molten composition downward from a nozzle having multiple orifices to obtain continuous loop fibers in a molten state, (c) Further comprising the step of cooling the loop fibers.

[0065] In further embodiments of this disclosure, the method (d) Further comprising the step of bringing loop fibers coated with at least one flame retardant and an optional binder into contact with each other and thermally bonding them, thereby forming a three-dimensional loop material with a random loop structure.

[0066] In another embodiment of the present disclosure, the method further includes, prior to step (ii), bringing the loop fibers into contact with each other and thermally bonding them, thereby forming a three-dimensional loop material with a random loop structure.

[0067] In some embodiments, melting is carried out at temperatures in the range of 170°C to 220°C, for example, 170°C to 210°C, 180°C to 210°C, or 180°C to 200°C.

[0068] In some embodiments, cooling is performed at temperatures in the range of 25°C to 40°C, for example, 30°C to 40°C, or 30°C to 35°C.

[0069] In some embodiments, steps (c) and (d) can be carried out simultaneously in a cold bath containing, for example, at least one flame retardant and an optional binder.

[0070] In some embodiments, the method further includes the step of drying the formed three-dimensional loop material before use or storage.

[0071] VIII. Use of Three-Dimensional Loop Materials This disclosure also provides the use of a three-dimensional loop material as a cushioning material.

[0072] Three-dimensional loop material can be adapted to a variety of applications. Examples include, but are not limited to, the use of three-dimensional loop material in chairs, stools, household furnishings, beds, sofas, mattresses, pillows, automobiles, motorcycles, trains, airplanes, boats, ships, vessels, aircraft, spacecraft, tractors, bicycles, unicycles, tricycles, recreational vehicles, dune buggies, jet skis, stadium seats, spacecraft, hovercraft, ski lifts, roller coasters, gliders, luge, bobsleighs, recliners, gurneys, beds, yoga mats, pet crate liners, gardening knee mats, or any other type of cycle, vehicle, seat, or furnishing. In some embodiments, three-dimensional loop material is used for seats in automobiles, motorcycles, trains, airplanes, boats, ships, aircraft, spacecraft, etc. In some embodiments, three-dimensional loop material is used for chairs, stools, household furnishings, beds, sofas, mattresses, pillows, etc.

[0073] When the three-dimensional loop material provided herein is used as a cushioning material, the specific polymer, fineness, fiber diameter, and bulk density used should be selected according to the purpose of use and the location where it is used.

[0074] In some embodiments, the three-dimensional loop material provided herein can be used to form a structure into a suitable shape using a mold or the like, to the extent that the three-dimensional loop material is not damaged, and then to cover it with an outer wrap or top wrap.

[0075] This disclosure further provides a vehicle seat comprising the three-dimensional loop material disclosed herein.

[0076] Please understand that both the general description above and the detailed description below are illustrative and descriptive, and do not limit the claimed invention. [Examples]

[0077] Next, some embodiments of the present invention will be described in the following examples. Here, all parts and percentages are given by weight unless otherwise specified.

[0078] A. Materials / Ingredients [Table 1]

[0079] B. Flame retardant coating process As shown in Table 2, the FR aqueous solution was obtained by directly using a commercially available FR product from Guochuang. The FR / binder solution was obtained by simply mixing the commercially available FR product with the binder solution. FR coating of 3DL articles was achieved by both spraying and immersion in the obtained FR / binder solution. The coated articles were then transferred to an oven at 85°C and dried for 22 hours.

[0080] The amount of FR filling in the coating was obtained by the following formula.

[0081]

number

[0082] The test specimen size for the 3DL article used in the horizontal combustion test was 50mm x 100mm x 10mm.

[0083] [Table 2-1]

[0084] [Table 2-2] 1&2 :FR filler is blended with a binder and used as a coating material. 3 Using a conventional blending / filling process

[0085] C. Characteristic Testing FR-coated 3DL test specimens were subjected to durability testing (80,000 constant displacement repeated compressions on MTS810), and then the packing loss was recorded to test the FR performance. Because wear may differ between the top and bottom surfaces during durability testing, the top and bottom surfaces (10 mm thick) were cut separately from the specimen used for combustion testing. The results are summarized in Table 5. FR / binder formulations can effectively stabilize the coating during testing. Packing loss of coatings using FR alone is more severe than that of FR / binder formulations. High packing loss impairs FR performance during combustion testing, as shown in Table 5.

[0086] [Table 3]

[0087] The coating layer stabilized during the aging test (90°C, 200 hours), as summarized in Table 6. FR performance can be maintained during post-aging combustion tests.

[0088] [Table 4]

[0089] The coating layer did not affect the physical properties, including heat resistance (residual strain at 70°C) and durability (both thickness loss and hardness loss), as shown in Tables 7 and 8.

[0090] [Table 5] * std<5%

[0091] [Table 6] * std<5%

[0092] D. Measurement information 1. Melt Index The melt index was tested using a Tinius Olsen MP600 according to ASTM D1238. To meet the fiber extrusion requirements, the polymer melt index is in the range of 2–20 g / 10 min.

[0093] 2. Flexural modulus The flexural modulus of the polymer was measured using an Instron 5566 according to ASTM D790. The secant line at 2% was used as the test result for flexural modulus. Flexural modulus directly affects the bending resistance of 3D loop fibers, which is a crucial factor influencing the 3D loop cushion hardness. Generally, using more fillers in the polymer formulation results in compounds with higher flexural modulus. To control this effect of hardness on POE 3D loops, the target flexural modulus of the polymer compound was set at 64 ± 5 ​​MPa, and an acceptable flexural modulus was defined as less than 70 MPa.

[0094] 3.Hardness Hardness was measured according to ASTM D2240, and the Shore D method was used for these test specimens. The use of more filler resulted in a higher hardness polymer compound, and the inventors' target material hardness was 40 ± 3D.

[0095] 4. Compression Residual Strain The compression set of a plastic plate was measured according to ASTM D3574-2017. The test specimen was a 20cm × 20cm square 3D loop plate with a uniform thickness of approximately 5cm. After compressing with a 50% strain at 70°C for 22 hours using a compression fixture, the compression was removed and the 3D loop specimen was allowed to recover at room temperature for 30 minutes. The final thickness of the specimen was measured and the compression set was calculated using the following formula. Compression residual strain (%) = [(T o -T f ) / T o ]×100 In the formula, T o This is the original specimen thickness, T f This is the final specimen thickness.

[0096] 5. Aging conditions The sample was placed in an oven set to 90°C and left undisturbed for 200 hours.

[0097] 6. Mixing: All polymer formulations were prepared using a twin-screw extruder ZSK18 with a diameter of 18 mm and an L / D ratio of 40. The profile temperature was set to 70-140°C, and an output of 500 RPM and 10 kg / h was used during preparation. The screw design is shown in Figure 1.

[0098] 7. Durability test conditions: Figure 2 shows the durability test of FR coated specimens and samples. The durability of the 3D loop specimens was measured with an MTS 810 according to JIS K 6400-4 6.2 B, and the hardness of the cushioning material was characterized using indentation load deflection (ILD). The impact load was set to 750 ± 20 N (simulating the weight of an adult), and the push head was a 20 cm round disc with a rounded edge (similar to the contact area with the buttocks), with 80,000 impact cycles to simulate daily use for 7 years. The specimens were then left under stress-free conditions for 10 ± 0.5 minutes, and then the final hardness and thickness were characterized.

[0099] 8. Horizontal combustion test Flame resistance tests were conducted at the Shanghai Dow Center lab. Horizontal combustion rate tests of 3D loop articles were performed using an ATLAS horizontal combustion chamber. 3D loop samples were cut to a size of 356 × 50 × 30 mm, and the original surface of the product was pointed towards the flame. The combustion rate was calculated using the following formula. Five samples were used for the calculation for each sample, and the maximum combustion rate from these five samples was taken as the test result.

[0100]

number

[0101] To achieve superior flame resistance, the target horizontal burning rate for the 3D loop was set to less than 20 mm / min.

[0102] Variations and modifications exist from the embodiments described. Finally, any numbers disclosed herein should be interpreted as approximations, regardless of whether the words “about” or “approximately” are used to describe the numbers. The appended claims are intended to encompass all such modifications and variations that fall within the scope of the invention.

Claims

1. A three-dimensional loop material comprising loop fibers of polyethylene or ethylene / α-olefin elastomer coated with at least one flame retardant, wherein the loop fibers contain 0.5% to 40% by weight of the flame retardant based on the total weight of the loop fibers.

2. The three-dimensional loop material according to claim 1, wherein the flame retardant is a halogen-free flame retardant.

3. The three-dimensional loop material according to claim 1 or 2, wherein the loop fibers are coated with a mixture of at least one flame retardant and at least one binder, and the weight ratio of the flame retardant to the binder is 1:(0.05 to 5).

4. The three-dimensional loop material according to claim 1, wherein the at least one halogen-free flame retardant includes phosphates, phosphonates, and combinations thereof.

5. The three-dimensional loop material according to claim 2, wherein the at least one halogen-free flame retardant is selected from the group consisting of cyclic phosphonates, triaryl phosphates, cresyl diphenyl phosphates, tricresyl phosphates, trixylyl phosphates, triethyl phosphates, isodecyl diphenyl phosphates, oligomeric phosphate-phosphonates, cyclic organophosphates and phosphonates, nitrogen-containing polyol phosphates, and any combination thereof.

6. The three-dimensional loop material according to claim 1, wherein the ethylene / alpha-olefin copolymer contains 60% to 90% by weight of ethylene in the copolymer.

7. The ethylene / alpha-olefin copolymer contains 10% to 40% by weight of C in the copolymer. ４～１０ A three-dimensional loop material according to claim 1, comprising alpha-olefin.

8. Said C ４～１０ The three-dimensional loop material according to claim 5, wherein the alpha-olefin contains 1-octene.

9. The three-dimensional loop material according to claim 1, wherein the loop fibers of polyethylene or ethylene / α-olefin elastomer have a melting index (MI) in the range of 2 to 20 g / 10 min.

10. The three-dimensional loop material according to claim 1, wherein the horizontal burning rate of the three-dimensional loop material is less than 100 mm / min.

11. The three-dimensional loop material according to claim 1, wherein the flexural modulus of the loop fibers made of polyethylene or ethylene / α-olefin elastomer is less than 100 MPa.

12. The three-dimensional loop material according to claim 1, wherein the loop fibers of polyethylene or ethylene / α-olefin elastomer further comprise 0.3% to 10% by weight of an expandable flame retardant based on the weight of the loop fibers, the expandable flame retardant being selected from the group consisting of ammonium polyphosphate, polymeric piperazine pyrophosphate, melamine phosphate, and expandable blends.

13. A method for manufacturing a three-dimensional loop material according to claim 1, (i) A step of providing a loop fiber of polyethylene or ethylene / α-olefin elastomer, (ii) A method comprising the step of coating loop fibers with at least one flame retardant and an optional binder.

14. A vehicle seat comprising the three-dimensional loop material described in claim 1.

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