Composite sheet product and method for manufacturing same
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Solution Overview
Problem
Existing composite sheet products made of ultrafine fibers and elastomers struggle to achieve both high flame-retardant performance and strong sticking performance between the skin sheet and woven or knitted fabrics, often compromising on one aspect due to the use of halogen flame retardants or inadequate resin distribution.
Innovation Solution
A composite sheet product with a skin sheet of ultrafine fibers and a woven or knitted fabric, laminated with a resin layer containing a phosphorus or inorganic flame retardant and an adhesive layer, where the woven or knitted fabric has nap or ruggedness to enhance adhesion, and the adhesive is a thermoplastic resin with a softening temperature of 70 to 160°C, such as a nylon resin.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a large amount of flame retardant resin composition is added to the back surface of the sheet product, then flame-retardant performance is improved, but sticking performance between the sheet product and the woven or knitted fabric deteriorates
Solution Approach 1:
The invention divides the functional layer into two distinct layers: a flame retardant resin composition layer and an adhesive layer. This segmentation allows each layer to perform its specific function independently - the flame retardant layer provides fire safety without interfering with adhesion, while the separate adhesive layer ensures strong bonding to the woven or knitted fabric, even when thick fabrics are used.
Solution Approach 2:
The adhesive layer acts as an intermediary between the flame retardant resin composition layer and the woven or knitted fabric. It mediates the bonding interface, ensuring that the flame retardant composition does not directly contact the fabric and compromise adhesion, while still achieving both flame retardancy and strong sticking performance.
2Reliability
If halogen flame retardants are used to render materials flame retardant, then flame-retardant performance is improved, but harmful halogen gas is generated during burning
Solution Approach 1:
The invention replaces harmful halogen flame retardants with a flame retardant resin composition based on acrylic resins that do not generate harmful halogen gases during burning. This substitution maintains effective flame-retardant performance while eliminating the harmful byproduct, converting a harmful chemical approach into a safer alternative.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides a composite sheet product with high flame-retardant performance, non-toxic during burning, and excellent sticking performance, suitable for vehicle interiors, while maintaining a soft touch and dense appearance.
Implementation Method 1
an adhesive layer interposed therebetween
Implementation Method 2
the adhesive is a thermoplastic resin with a softening temperature of 70 to 160°C
Implementation Method 3
a resin layer containing a phosphorus or inorganic flame retardant
Data Source
AI summary
The present invention provides a composite sheet product that includes a skin sheet including a nonwoven fabric as a base and an elastomer impregnated into the nonwoven fabric, and a woven or knitted fabric, and that achieves both high flame-retardant performance and sticking performance between the skin sheet and the woven or knitted fabric, and a method for manufacturing the same. The composite sheet product of the present invention is a composite sheet product including: a skin sheet including a sheet product made of ultrafine fibers having an average monofilament diameter of 0.1 to 10 µm and an elastomer, and a woven or knitted fabric that are laminated on each other, and the skin sheet and the woven or knitted fabric are laminated on each other with a resin layer containing a flame retardant and an adhesive layer interposed therebetween. The method for manufacturing a composite sheet product of the present invention is a method including the following steps 1 to 3: 1. adding a resin containing a flame retardant to a skin sheet including ultrafine fibers having an average monofilament diameter of 0.1 to 10 µm and an elastomer; 2. imparting nap or unevenness to at least one surface of a woven or knitted fabric; and 3. sticking, with an adhesive, a surface of the skin sheet obtained in step 1, the surface having the resin containing the flame retardant, to the surface of the woven or knitted fabric obtained in step 2, the surface having nap or unevenness.