CN114474909A

CN114474909A - Flame-retardant carpet substrate layer and flame-retardant carpet

Info

Publication number: CN114474909A
Application number: CN202210097508.2A
Authority: CN
Inventors: 蒋宝林; 孙长庆; 杨冰; 张磊
Original assignee: Guangdong Huitian Aerospace Technology Co Ltd
Current assignee: Guangdong Huitian Aerospace Technology Co Ltd
Priority date: 2022-01-27
Filing date: 2022-01-27
Publication date: 2022-05-13

Abstract

The application provides a fire-retardant carpet substrate layer and fire-retardant carpet, this fire-retardant carpet substrate layer includes fire-retardant PET fiber material and low melting point PET fiber material at least, and fire-retardant PET fiber material adopts phosphorus system fire-retardant, and the quality of fire-retardant PET fiber material accounts for than being 60% -80%, and the quality of low melting point PET fiber material accounts for than being 20% -30%. The application provides a fire-retardant carpet substrate layer, fire-retardant PET fiber material adopts phosphorus system fire-retardant, satisfies the law requirement under two kinds of operating modes of flight and land, and provides certain flame retardant efficiency through fire-retardant PET fiber material, and low melting point PET fiber material plays the shaping effect for fire-retardant carpet substrate layer still has good formability under the condition that satisfies aviation high standard fire-retardant requirement, can be applicable to the air-ground amphibious manned aircraft.

Description

Flame-retardant carpet substrate layer and flame-retardant carpet

Technical Field

The application relates to the technical field of carpets, in particular to a flame-retardant carpet substrate layer and a flame-retardant carpet.

Background

An air-ground amphibious manned vehicle is a manned vehicle which can run on the ground and can also fly on the sky. However, at present, no carpet suitable for an air-ground amphibious manned aircraft exists so as to meet the design and use requirements under two working conditions of flight and land running.

The related technology provides a civil aviation carpet, which is made of wool, and the wool surface layer is subjected to flame retardant treatment so as to meet the flame retardant performance requirements of standards such as CCAR25.853/CCAR23.853/CTSO-2C601 in the civil aviation field. However, the carpet for civil aviation is a simple planar modeling, cannot meet the structural design requirements (such as a molded surface, different thicknesses in different regions, a boss structure, stiffness, support and the like) of the air-ground amphibious manned vehicle, and cannot meet the performance development requirements of the air-ground amphibious manned vehicle on breaking strength, breaking elongation, high and low temperature resistance, cold and hot alternation resistance, wear resistance and the like.

The related art also provides an automotive carpet, which can be structurally designed, but the flame retardant property can not meet the requirement of vertical combustion in the field of aviation. At present, the requirements of GB8410 are implemented in the flame retardant test of the car carpet, wherein a horizontal combustion test mode is adopted, the combustion rate is required to be lower than 100mm/min, while a vertical combustion test mode is adopted for the civil aviation carpet, after 12 seconds of vertical combustion, the flame needs to be self-extinguished within 15 seconds, the scorching length is less than or equal to 203mm, and the drop extinguishing time is less than or equal to 5 seconds.

For carpets, the carpet substrate layer plays an important role in carpet molding, and provides support, sound absorption, and the like for the carpet. In addition, in the test verification, the flame can be conducted to the base material layer and spread if the carpet base material layer material is not flame-retardant in the vertical burning test, and the vertical burning time, the burning length and the like all exceed the standard requirements. Therefore, how to design a carpet substrate layer meeting design and use requirements under two working conditions of flight and land, which is the key point that the carpet can be suitable for the air-ground amphibious manned vehicle.

Disclosure of Invention

The application aims to provide a flame-retardant carpet substrate layer and a flame-retardant carpet so as to solve or improve the problems. The present application achieves the above object by the following technical solutions.

In a first aspect, an embodiment of the application provides a flame-retardant carpet substrate layer, the flame-retardant carpet substrate layer at least comprises a flame-retardant PET fiber material and a low-melting-point PET fiber material, the flame-retardant PET fiber material is flame-retardant by using phosphorus, the mass percentage of the flame-retardant PET fiber material is 60% -80%, and the mass percentage of the low-melting-point PET fiber material is 20% -30%.

In a second aspect, the embodiment of the application provides a fire-retardant carpet, including pile top layer, syllable-dividing adhesive linkage and fire-retardant bottom and the first aspect fire-retardant carpet substrate layer, pile top layer, syllable-dividing adhesive linkage, fire-retardant carpet substrate layer and fire-retardant bottom stack gradually the setting.

According to the flame-retardant carpet base material layer and the flame-retardant carpet provided by the embodiment of the application, the flame-retardant PET fiber material is flame-retardant by adopting a phosphorus system, so that the regulatory requirements under two working conditions of flight and land are met; meanwhile, the flame-retardant PET fiber material provides a certain flame-retardant effect, the low-melting-point PET fiber material plays a forming role, the flame-retardant carpet substrate layer still has good formability under the condition that the aviation high-standard flame-retardant requirement is met by setting the mass ratio of the flame-retardant PET fiber material to be 60-80% and the mass ratio of the low-melting-point PET fiber material to be 20-30%, and the flame-retardant carpet substrate layer can be suitable for an air-ground amphibious manned aircraft.

Drawings

In order to more clearly illustrate the technical solutions in the embodiments of the present application, the drawings needed to be used in the description of the embodiments are briefly introduced below, and it is obvious that the drawings in the following description are only some embodiments of the present application, and it is obvious for those skilled in the art to obtain other drawings based on these drawings without creative efforts.

Fig. 1 is a schematic structural diagram of a flame-retardant carpet substrate layer provided in an embodiment of the present application.

Fig. 2 is a schematic structural diagram of a flame retardant carpet provided in an embodiment of the present application.

Fig. 3 is a schematic structural view of a flame retardant carpet provided in another embodiment of the present application.

Fig. 4 is a schematic flow chart of a method of manufacturing the flame retardant carpet shown in fig. 2.

Fig. 5 is a schematic flow chart of a method of manufacturing the flame retardant carpet shown in fig. 3.

Detailed Description

Reference will now be made in detail to embodiments of the present application, examples of which are illustrated in the accompanying drawings, wherein like or similar reference numerals refer to the same or similar elements or elements having the same or similar function throughout. The embodiments described below with reference to the accompanying drawings are illustrative and are only for the purpose of explaining the present application and are not to be construed as limiting the present application.

At present, the requirements of GB8410 are implemented in the flame retardant test of the car carpet, wherein a horizontal combustion test mode is adopted, the combustion rate is required to be lower than 100mm/min, while a vertical combustion test mode is adopted for the civil aviation carpet, the flame needs to be self-extinguished within 15s after 12s of vertical combustion, the burning length is less than or equal to 203mm, and the extinguishing time of the drops is less than or equal to 5 s. In addition, the aviation carpet carries out stricter limit values on smoke density and toxic gas content in the combustion process, wherein the smoke density requires that the maximum smoke density Ds value is not more than 200 after 4min, CO released by toxic gas is not more than 3500X 10-6, HCN is not more than 150X 10-6, HF is not more than 100X 10-6, HCL is not more than 150X 10-6, SO2 is not more than 100X 10-6, and NOX is not more than 100X 10-6.

The conventional carpet for civil use can not be structurally designed, the performances of breaking strength, breaking elongation, high and low temperature resistance, cold and hot alternation resistance, wear resistance, sound absorption and sound insulation and the like are far lower than the requirements of automobiles, and meanwhile, VOC, smell, atomization and the like can not meet the technical requirements of the air quality of automobile interiors (the requirements of formaldehyde is less than or equal to 200 mu g/m3, acetaldehyde is less than or equal to 150 mu g/m3, acrolein is less than or equal to 30 mu g/m3, benzene is less than or equal to 50 mu g/m3, toluene is less than or equal to 250 mu g/m3, ethylbenzene is less than or equal to 100 mu g/m3, xylene is less than or equal to 200 mu g/m3, styrene is less than or equal to 100 mu g/m3, the normal-temperature 23-DEG odor strength is less than or equal to 3 grade, the 40-DEG humidity environment odor strength is less than or equal to 3 grade, the 80-DEG odor strength is less than or equal to 3.5 grade, and the atomization value is less than or equal to 2 mg).

Specifically, according to the standards of CCAR25.853/CCAR23.853/CTSO-2C601 and the like in the civil aviation field, a 12-second vertical burning test is carried out on the automobile carpet material provided by the related technology, and the test result shows that the carpet has the lasting burning time of more than 120s and the burning length of more than 305mm, and the flame retardant property can not meet the requirements of the civil aviation field. The carpet base material plays an important role in carpet forming, and provides support, sound absorption and the like for the carpet. In addition, the test verifies that in the vertical burning test, if the carpet base material layer is not flame-retardant, flame can be conducted to the base material layer and spread, and the vertical burning time, the burning length and the like all exceed the standard requirements.

The design of the carpet of the air-ground amphibious manned aircraft needs to meet the design and use requirements under two working conditions of flight and land, indexes such as flame retardance, smoke density and toxic gas release need to be executed according to civil aviation system regulations, the strict structural design of the automobile carpet needs to be met, performance indexes such as tensile, environment resistance and abrasion resistance need to be met, and various regulations in the automobile field, such as forbidden material regulations, need to be met at the same time. With the increase of health consciousness and environmental consciousness, consumers pay more attention to the air quality, smell and the like of automobile interiors.

In addition, the conventional flame retardant technology comprises a halogen-containing flame retardant system containing bromine, chlorine and the like, a phosphorus-containing flame retardant system containing phosphorus elements, a nitrogen-containing flame retardant system containing triazine structures and the like, and an inorganic flame retardant system containing aluminum hydroxide, magnesium hydroxide and the like, and the technical process comprises ways of copolymerization, blending, flame retardant post-treatment and the like. Among them, the halogen flame retardant system has excellent flame retardant effect, but polybrominated biphenyls and polybrominated diphenyl ethers are definitely forbidden in the national automobile regulation GB 30512, while the halogen flame retardant system can release a large amount of toxic and corrosive gas during combustion, and part of halogen compounds also have carcinogenicity, mutation-causing type, long-term pollution and the like, so the halogen-containing flame retardant is gradually eliminated by the market at present. The inorganic flame retardant has the problems of uneven dispersion in the PET fibers, influence on the molding and strength of the protofilament fibers and the like.

In view of the above, the inventor of the present invention provides a flame retardant carpet substrate layer and a flame retardant carpet, wherein the flame retardant carpet substrate layer comprises a flame retardant PET fiber material and a low melting point PET fiber material, and the flame retardant PET fiber material adopts a phosphorus flame retardant, so as to meet the regulatory requirements under two working conditions of flight and land; the flame-retardant PET fiber material provides a certain flame-retardant effect, the low-melting-point PET fiber material plays a forming role, the flame-retardant PET fiber material is 60-80% in mass percentage and the low-melting-point PET fiber material is 20-30% in mass percentage, so that the flame-retardant carpet base material layer still has good formability under the condition of meeting the aviation high-standard flame-retardant requirement, and can be suitable for an air-ground amphibious manned aircraft.

In order to make the technical solutions better understood by those skilled in the art, the technical solutions in the embodiments of the present application will be clearly and completely described below with reference to the drawings in the embodiments of the present application. It is to be understood that the embodiments described are only a few embodiments of the present application and not all embodiments. All other embodiments obtained by a person skilled in the art based on the embodiments in the present application without making any creative effort belong to the protection scope of the present application.

Referring to fig. 1, an embodiment of the present application provides a flame-retardant carpet substrate layer 10, where the flame-retardant carpet substrate layer 10 at least includes a flame-retardant PET fiber material and a low-melting-point PET fiber material, the flame-retardant PET fiber material is flame-retardant by using a phosphorus system, a mass ratio of the flame-retardant PET fiber material is 60% to 80%, and a mass ratio of the low-melting-point PET fiber material is 20% to 30%. The flame-retardant PET fiber material is used for providing a certain flame-retardant effect for the flame-retardant carpet base material layer 10, and the low-melting-point PET fiber material plays a forming role.

For fiber materials, flame retardance and moldability cannot be considered at the same time, and when the content of the flame retardant is large, molding is difficult and the fiber materials cannot be suitable for various application occasions; when the content of the flame retardant is low, the flame retardant requirement cannot be met. In the embodiment, the mass percentage of the flame-retardant PET fiber material is set to be 60-80%, the mass percentage of the low-melting-point PET fiber material is set to be 20-30%, and the content of the low-melting-point PET fiber material reaches a certain percentage, so that the flame-retardant carpet base material layer 10 has good comprehensive effects of flame retardance and formability, and still has good formability under the condition of ensuring high-standard flame-retardant requirements of aviation; meanwhile, the flame-retardant PET fiber material is flame-retardant by adopting a phosphorus system, and meets the regulatory requirements under two working conditions of flight and land, so that the flame-retardant carpet base material layer 10 can be suitable for an air-ground amphibious manned aircraft.

The flame retardant carpet substrate layer 10 is generally used as an intermediate layer of a carpet or directly as a bottom layer, and the flame retardant carpet substrate layer 10 mainly plays a role in molding the whole carpet and provides a supporting and sound absorbing function for the carpet. Through the compression molding process, the flame-retardant carpet base material layer 10 can be correspondingly molded, and the design requirements of carpet molded surfaces, different areas, different thicknesses and the like are met.

When the flame retardant carpet substrate layer 10 is used as the middle layer of the carpet, the carpet may also typically include a raised surface layer overlying the upper surface of the flame retardant carpet substrate layer 10, and a base layer overlying the lower surface of the flame retardant carpet substrate layer 10, in the overall carpet construction. When the flame-retardant carpet substrate layer 10 is directly used as the bottom layer of the carpet, the carpet may generally further include a raised surface layer stacked on the upper surface of the flame-retardant carpet substrate layer 10, and the lower surface of the flame-retardant carpet substrate layer 10 is directly laid on an air-ground amphibious manned aircraft. With regard to the specific structure of the raised top layer and the bottom layer, reference may be made to the following examples in connection with flame retardant carpets. The upper surface is the surface of the flame-retardant carpet base material layer 10 far away from the air-ground amphibious manned aircraft during use, and the lower surface is the surface of the flame-retardant carpet base material layer 10 facing the air-ground amphibious manned aircraft during use. Of course, in some embodiments, the carpet may also include only the flame retardant carpet substrate layer 10.

As an example, in the flame-retardant carpet base material layer 10, the mass percentage of the flame-retardant PET fiber material may be 80%, and the mass percentage of the low-melting point PET fiber material may be 20%. Or the mass percentage of the flame-retardant PET fiber material is 70 percent, and the mass percentage of the low-melting-point PET fiber material is 30 percent.

Considering that in the carpet structure, the moldability of the carpet is mainly determined by the flame-retardant carpet base material layer 10, and the flame retardancy is mainly determined by other functional layers except the flame-retardant carpet base material layer 10, the mass ratio of the flame-retardant PET fiber material in the flame-retardant carpet base material layer 10 can be reduced to 60% -75%, and the mass ratio of the low-melting point PET fiber material can be increased to 25% -30%, so as to improve the moldability of the flame-retardant carpet base material layer 10.

In this embodiment, the manufacturing process of the flame-retardant carpet base material layer 10 may be as follows: the low-melting-point PET fiber material and the flame-retardant PET fiber material adopting the phosphorus flame retardant are fed, opened, mixed, carded and lapped according to a set proportion to form the flame-retardant carpet base material layer 10.

The flame-retardant PET fiber material can adopt any one of phosphorus-based copolymerization flame retardance, phosphorus-based blending flame retardance or phosphorus-nitrogen-based blending flame retardance. The flame-retardant modes belong to permanent flame retardance, the flame-retardant effect cannot be reduced along with the use, cleaning and other factors of carpets, substances forbidden and limited in regulations are not added into the phosphorus flame retardant, and the flame-retardant fibers meet the regulation requirements of ELV (vehicle scrapping instruction), European Union REACH (chemical registration, evaluation, authorization and limitation), European Union POPs (persistent organic pollutant recasting regulations) and the like. The copolymerization modified flame-retardant PET fiber material has less addition of small molecular flame retardant, and indexes such as VOC, odor property, atomization and the like are better than other flame-retardant modes.

The phosphorus flame retardant can be added into the fiber raw material by a physical or chemical method, so that the phosphorus flame retardant is uniformly distributed in the fiber and is tightly combined with the fiber. For example, through copolymerization flame-retardant modification, flame-retardant elements participate in the polymerization process of fiber polymers, so that the flame retardant is combined into macromolecular chains of the polymers to achieve a long-term flame-retardant result; or, the flame retardant is added into the spinning melt or the solution to be spun into the flame-retardant fiber through blending flame-retardant modification, and the flame retardance and the durability of the flame-retardant fiber are far superior to those of the flame-retardant PET fiber subjected to post-treatment such as dipping, coating and the like.

Of course, the flame retardant PET fiber material is not limited to a single phosphorus flame retardant. The flame-retardant PET fiber material can also adopt a synergistic flame-retardant mode combining phosphorus flame retardance and nitrogen flame retardance or combining phosphorus flame retardance, nitrogen flame retardance and inorganic hydroxide flame retardance.

In some embodiments, the flame-retardant carpet base layer 10 further includes a low-melting-point flame-retardant PET fiber material that is flame-retardant by using a phosphorus system, and the mass ratio of the low-melting-point flame-retardant PET fiber material may be 0% to 30%. Compared with the low-melting-point PET fiber material, the low-melting-point flame-retardant PET fiber material has better flame-retardant effect. Illustratively, in the flame-retardant carpet base material layer 10, the mass percentage of the flame-retardant PET fiber material is 60%, the mass percentage of the low-melting-point PET fiber material is 30%, and the mass percentage of the low-melting-point flame-retardant PET fiber material is 10%.

In this embodiment, the flame retardant manner of the low melting point flame retardant PET fiber material may be the same as that of the flame retardant PET fiber material, and the mass percentage of the phosphorus element in the low melting point flame retardant PET fiber material may be 0.8% to 1%.

In some embodiments, the low-melting-point PET fiber material may also be partially or completely a low-melting-point flame retardant PET fiber material adopting a phosphorus flame retardant system, so as to further improve the flame retardant effect of the flame retardant carpet base material layer 10.

As an example, the low melting point PET fiber material part is a low melting point flame retardant PET fiber material using a phosphorus flame retardant, and the flame retardant carpet substrate layer 10 includes a flame retardant PET fiber material, a conventional low melting point PET fiber material, and a low melting point flame retardant PET fiber material. As another example, the low melting point PET fiber materials are all low melting point flame retardant PET fiber materials flame retardant by using phosphorus system, in this case, the flame retardant carpet substrate layer 10 may only include the flame retardant PET fiber material and the low melting point flame retardant PET fiber material, for example, the weight ratio of the flame retardant PET fiber material in the flame retardant carpet substrate layer 10 is 70%, and the weight ratio of the low melting point flame retardant PET fiber material is 30%.

In some embodiments, the flame retardant PET fiber material has a phosphorus content of 0.8% to 1% by weight. Therefore, the problems that the flame-retardant PET fiber material cannot meet the flame-retardant requirement of an aircraft carpet when the phosphorus content in the flame-retardant PET fiber material is low, the phosphorus content in the flame-retardant PET fiber material is too high, and great difficulty and challenge are brought to spinning, forming and the like of fibers can be solved, so that the flame-retardant requirement of civil aviation can be met, the processability of the fibers can be guaranteed, and mass production can be realized. Illustratively, the mass percentage of the phosphorus element in the flame-retardant PET fiber material may be equal to 0.8%, 0.9%, 0.95%, or 1%, and so on.

In this embodiment, the mass percentage of the phosphorus element in the flame-retardant PET fiber material can be reduced to 0.85% -0.95%, so as to further optimize the flame retardancy and the processability of the flame-retardant PET fiber material.

In some embodiments, the flame retardant PET fiber material has a limiting oxygen index greater than 31. The limiting oxygen index refers to the volume fraction concentration of oxygen in the oxygen and nitrogen mixed gas when just supporting the combustion of the polymer, and the larger the limiting oxygen index is, the flame-retardant material is indicated. The limit oxygen index is larger than 31, which indicates that the flame-retardant PET fiber material belongs to a flame-retardant material and meets the flame-retardant requirement of civil aviation. In this embodiment, the limiting oxygen index of the flame retardant PET fiber material may be equal to 32, 34, 35, 36, or the like.

In some embodiments, the low melt PET fiber material has a melting point of 115 deg.C to 130 deg.C. The melting point of the flame-retardant PET fiber material is higher than that of the low-melting-point PET fiber material, and in the manufacturing process, the low-melting-point PET fiber material can be melted at the temperature lower than that of the flame-retardant PET fiber material, so that the flame-retardant PET fiber materials are bonded with each other, and the forming effect is achieved.

In some embodiments, the grammage of the flame retardant carpet substrate layer 10 is 400g/m2-600g/m 2. The thickness of the flame-retardant carpet base material layer 10 is 3mm-5 mm. The fiber fineness of the flame-retardant PET fiber material is 8D-15D, and the fiber length is 51mm-90 mm. The fiber fineness of the low-melting-point PET fiber material is 4D, and the fiber length is 51mm-90 mm. The fiber number of the flame-retardant PET fiber material is in a large range, and the tensile fracture in the forming process can be avoided. Through the combined requirements of the fineness, the fiber length and the gram weight of the materials, the flame-retardant carpet base material layer 10 can meet the requirements of the air-ground amphibious aircraft carpet on flame retardance, stiffness, support, structural design, sound absorption, mechanical properties and the like.

Illustratively, the grammage of the flame retardant carpet substrate layer 10 may be equal to 400g/m2, 450g/m2, 500g/m2, 600g/m2, or the like. The thickness of the flame-retardant carpet base material layer 10 is 3mm, 4mm, 5mm or the like. The fiber fineness of the flame-retardant PET fiber material can be 8D, 10D, 12D, 15D and the like, and the fiber length can be equal to 51mm, 64mm, 76mm, 90mm and the like. The fiber length of the low melting point PET fiber material can be equal to 51mm, 64mm, 76mm, 90mm or the like.

In the embodiment, the gram weight of the flame-retardant carpet base material layer 10 can be further preferably 450g/m2-550g/m2, so as to ensure the comprehensive performance of the flame-retardant carpet base material layer 10.

The flame retardant carpet substrate layer 10 of the present invention is further described below by way of specific examples. The following examples are, of course, intended to illustrate the invention and are not intended to limit the scope of the invention.

Example one

The flame-retardant carpet base material layer 10 comprises a flame-retardant PET fiber material, a low-melting-point PET fiber material and a low-melting-point flame-retardant PET fiber material. The weight ratio of the flame-retardant PET fiber material is 70%, the weight ratio of the low-melting-point PET fiber material is 15%, and the weight ratio of the low-melting-point flame-retardant PET fiber material is 15%. The gram weight of the material of the flame retardant carpet substrate layer 10 is 500g/m 2. The flame-retardant PET fiber material is characterized in that the fiber fineness of the flame-retardant PET fiber material is 12D, the fiber length is 64mm, the flame-retardant method adopts phosphorus copolymerization flame retardance, and the phosphorus content in the flame-retardant PET fiber material is 0.9% by mass. The low-melting-point PET fiber material has a fiber fineness of 4D and a fiber length of 51 mm. The fiber fineness and the fiber length of the low-melting-point flame-retardant PET fiber material are consistent with those of the low-melting-point PET fiber material, and the phosphorus content in the low-melting-point flame-retardant PET fiber material is 0.9 percent by mass. The flame-retardant PET fiber material, the low-melting-point PET fiber material and the low-melting-point flame-retardant PET fiber material are mixed, carded, lapped and compounded.

Test verification results show that the mould pressing test piece with the length of 320mm multiplied by the width of 90mm is prepared, 12-second vertical combustion test is carried out, after a fire source is removed, flames are extinguished within 10s, no drop is generated, and the flame retardant effect is excellent. A sample with the length of 350mm multiplied by the width of 50mm is taken, the sample is clamped by 200mm, the sample is stretched at the stretching rate of 200mm/min, the breaking strength is greater than 200N, the breaking elongation is greater than 20%, a trapezoid sample with the short side of 100mm and the long side of 150mm is manufactured, a notch with the length of 10mm, which is perpendicular to the short side, is cut in the middle of the short side, the breaking tension of the sample along the extension line direction of the notch is measured to be greater than 100N, the sample is not broken through stretching in the compression molding process, the forming performance is good, and after high temperature resistance, low temperature resistance and cold and heat exchange resistance tests, the abnormal phenomena of foaming, deformation, distortion, depression and the like do not occur, and all performance indexes of the flame-retardant carpet base material layer 10 material can meet the technical requirements.

Example two

The flame-retardant carpet base material layer 10 comprises a flame-retardant PET fiber material and a low-melting-point PET fiber material, the weight proportion of the flame-retardant PET fiber material in the base material layer is 80%, and correspondingly, the weight proportion of the low-melting-point PET fiber material in the base material layer is 20%. The gram weight of the material of the flame retardant carpet substrate layer 10 is 500g/m 2. The flame-retardant PET fiber material is characterized in that the fiber fineness of the flame-retardant PET fiber material is 12D, the fiber length is 64mm, the flame-retardant method adopts phosphorus copolymerization flame retardance, and the phosphorus content in the flame-retardant PET fiber material is 0.9% by mass. The low-melting-point PET fiber material has a fiber fineness of 4D and a fiber length of 51 mm. The flame-retardant PET fiber material and the low-melting-point PET fiber material are mixed, carded, lapped and compounded.

In the second embodiment, the weight ratio of the flame-retardant PET fiber material is increased, the phosphorus content mass percentage in the flame-retardant PET fiber material is increased, and the fiber fineness, the fiber length, the gram weight and the pile height are limited, so that the flame retardance of the flame-retardant carpet base material layer 10 is increased.

EXAMPLE III

The flame-retardant carpet base material layer 10 comprises a flame-retardant PET fiber material and a low-melting-point PET fiber material, the weight proportion of the flame-retardant PET fiber material in the base material layer is 70%, and correspondingly, the weight proportion of the low-melting-point PET fiber material in the base material layer is 30%. The gram weight of the material of the flame-retardant carpet base layer 10 is 400g/m 2. The flame-retardant PET fiber material has the fiber fineness of 15D and the fiber length of 64mm, the flame-retardant method adopts phosphorus copolymerization flame retardance, and the phosphorus content in the flame-retardant PET fiber material is 0.9% by mass. The low-melting-point PET fiber material has a fiber fineness of 4D and a fiber length of 51 mm. The flame-retardant PET fiber material and the low-melting-point PET fiber material are mixed, carded, lapped and compounded.

The embodiment improves the weight ratio of the low-melting-point PET fiber material, reduces the phosphorus content mass percentage in the flame-retardant PET fiber material, and limits the fiber fineness, the fiber length, the gram weight and the pile height so as to improve the formability of the flame-retardant carpet base material layer 10. In the first to third embodiments, the first embodiment has the best overall effects of flame retardant effect, smoke density and toxic gas amount, breaking strength and elongation, weight, formability, VOC, odor, cost, and the like.

The embodiment of the application determines the flame-retardant carpet base material layer 10 formed by mixing the flame-retardant PET fiber material and the low-melting-point PET fiber material through selection of a flame-retardant system, control of phosphorus content, selection of flame-retardant fiber titer and fiber length and content combination of the flame-retardant PET fiber material and the low-melting-point PET fiber material, and specifies the fabric gram weight of the flame-retardant carpet base material layer 10, so that the carpet design and the use requirements of the air-ground amphibious manned aircraft can be met.

Referring to fig. 2, an embodiment of the present application further provides a flame retardant carpet 100, which includes a raised surface layer 30, a sound insulation adhesive layer 50, a flame retardant bottom layer 70, and a flame retardant carpet substrate layer 10, wherein the raised surface layer 30, the sound insulation adhesive layer 50, the flame retardant carpet substrate layer 10, and the flame retardant bottom layer 70 are sequentially stacked.

According to the flame-retardant carpet 100 provided by the embodiment of the application, the flame-retardant carpet base material layer 10 comprises a flame-retardant PET fiber material and a low-melting-point PET fiber material, and the flame-retardant PET fiber material adopts a phosphorus flame retardant, so that the regulatory requirements under two working conditions of flight and land are met; meanwhile, the flame-retardant PET fiber material provides a certain flame-retardant effect, the low-melting-point PET fiber material plays a forming role, the flame-retardant carpet substrate layer still has good formability under the condition that the aviation high-standard flame-retardant requirement is met by setting the mass ratio of the flame-retardant PET fiber material to be 60-80% and the mass ratio of the low-melting-point PET fiber material to be 20-30%, and the flame-retardant carpet substrate layer can be suitable for an air-ground amphibious manned aircraft.

In some embodiments, the raised skin layer 30 may include a flame retardant PET fiber material and a low melting point PET fiber material, the flame retardant PET fiber material is flame retardant using a phosphorous system, and the surface of the raised skin layer 30 is raised. The surface of the napping surface layer 30 is napped, so that the requirements of the needling napping process of the air-ground amphibious manned aircraft are met; meanwhile, the flame retardant PET fiber material can improve the flame retardancy of the raised surface layer 30, and the low melting point PET fiber material plays a role in molding, so as to further improve the flame retardancy and the moldability of the flame retardant carpet 100.

The flame-retardant PET fiber material in the raised surface layer 30 can adopt phosphorus-based copolymerization flame retardant, phosphorus-based blending flame retardant or phosphorus-nitrogen-based blending flame retardant, the flame-retardant modes belong to permanent flame retardant, the flame-retardant effect cannot be reduced along with the use, cleaning and other factors of the carpet, and substances forbidden and limited in regulations are not added in the phosphorus-based flame retardant.

The low-melting-point PET fiber material in the raised surface layer 30 may also be partially or completely a low-melting-point flame-retardant PET fiber material adopting a phosphorus flame retardant, so as to further enhance the flame-retardant effect of the raised surface layer 30.

The mass percentage of the flame-retardant PET fiber material in the raised surface layer 30 is 70-95%, and the mass percentage of the low-melting-point PET fiber material is 5-30%. Therefore, the raised surface layer 30 has good comprehensive effects of flame retardance and formability, and still has good formability under the condition of ensuring the requirement of high-standard flame retardance in the air. The content of the low melting point PET fiber material in the flame retardant carpet substrate layer 10 may be greater than the content of the low melting point PET fiber material in the raised surface layer 30, so that the flame retardant carpet substrate layer 10 has better forming ability.

Illustratively, the mass percentage of the flame-retardant PET fiber material in the raised surface layer 30 may be 70%, and the mass percentage of the low-melting-point PET fiber material may be 30%; or the mass percentage of the flame-retardant PET fiber material is 80 percent, and the mass percentage of the low-melting-point PET fiber material is 20 percent; or the mass percentage of the flame-retardant PET fiber material is 85 percent, and the mass percentage of the low-melting-point PET fiber material is 15 percent; or the mass percentage of the flame-retardant PET fiber material is 95%, and the mass percentage of the low-melting-point PET fiber material is 5%.

Considering that in some embodiments, the moldability of the flame retardant carpet 100 is mainly determined by the flame retardant carpet substrate layer 10, and the raised surface layer 30 mainly determines the flame retardancy of the flame retardant carpet 100, it is preferable that the mass ratio of the flame retardant PET fiber material in the raised surface layer 30 is 85% to 95% and the mass ratio of the low melting point PET fiber material is 5% to 15%, so as to increase the flame retardancy of the raised surface layer 30 and maintain a certain molding effect by increasing the mass ratio of the flame retardant PET fiber material.

The flame-retardant PET fiber material of the raised surface layer 30 contains 0.8-1% of phosphorus by mass, so that the flame-retardant PET fiber material meets the flame-retardant requirement of civil aviation, can ensure the processability of the fiber, and can be produced in large quantities. Illustratively, the mass percentage of the phosphorus element in the flame-retardant PET fiber material may be equal to 0.8%, 0.9%, 0.95%, or 1%, and so on. Further, the mass percentage of the phosphorus element in the flame retardant PET fiber material may preferably be 0.85% to 0.95% to further optimize the flame retardancy and processability of the flame retardant PET fiber material.

The limit oxygen index of the flame-retardant PET fiber material in the raised surface layer 30 is larger than 31, and the flame-retardant requirement of civil aviation is met. The melting point of the low-melting-point PET fiber material is 115-130 ℃. In the processing and forming process, the low-melting-point PET fiber material can be melted at a temperature lower than the melting temperature of the flame-retardant PET fiber material, so that the flame-retardant PET fiber materials are bonded with each other, and the forming effect is achieved.

The raised skin layer 30 has a grammage of 300g/m2-600g/m 2. The fiber fineness of the flame-retardant PET fiber material in the raised surface layer 30 is 4D-8D, and the fiber length is 51mm-90 mm. The fiber fineness of the low-melting-point PET fiber material is 4D, and the fiber length is 51mm-90 mm. The nap height of the nap surface layer 30 is 3mm-5mm, the nap effect, the hand feeling and the appearance are good, and the carpet design requirement of the air-ground amphibious manned aircraft can be met. The raised surface layer 30 can meet the requirements of the air-ground amphibious manned aircraft on the carpet surface for needle raising, surface wear resistance, mechanics, sound absorption, formability and the like through the combination requirements of the fineness, the fiber length and the gram weight of the material.

The fiber number of the flame-retardant PET fiber material of the flame-retardant carpet base material layer 10 is larger than that of the flame-retardant PET fiber material of the napping surface layer 30, so that the strength requirement of the forming process is met, and the tensile fracture is avoided.

It should be noted that, when the gram weight of the raised surface layer 30 is fixed, the fineness of the flame-retardant PET fiber material is higher, the fiber bundles are more sparse after needling, the fineness is too high, and the raised surface layer 30 is sparse due to stretching in the forming process, so that the raised surface layer has poor hand feeling and appearance, and even the light transmission and sound absorption are worse. When the fiber fineness is too low, the flame-retardant PET fiber material is soft, and meanwhile, the needling raising effect is poor. For example, when a flame-retardant PET fiber material with a fiber limit of 3D and a fiber length of 51mm is needle-punched, the pile height is only about 2mm, and the needle-punched pile effect, the hand feeling and the appearance effect are poor, which cannot meet the design requirement of the carpet. In the embodiment, the raised surface layer 30 is prepared by mixing the flame-retardant PET fiber material and the low-melting-point PET fiber material in the range, so that the carpet design and the use requirements of the air-ground amphibious manned aircraft can be met.

Illustratively, the gram weight of the raised skin layer 30 may be 300g/m2, 350g/m2, 500g/m2, or 600g/m 2. The fiber fineness of the flame-retardant PET fiber material can be 4D, 6D or 8D and the like, and the fiber length can be equal to 51mm, 64mm, 76mm or 90mm and the like. The fiber length of the low melting point PET fiber material can be equal to 51mm, 64mm, 76mm, 90mm or the like. The pile height of the pile surface layer 30 may be equal to 3mm, 4mm, 4.5mm, 5mm, or the like.

In some embodiments, the soundproof adhesive layer 50 includes a first PE (polyethylene) film layer, a PA (Polyamide) film layer, and a second PE film layer, which are sequentially stacked. The PA film layer has certain flame retardance, the first PE film layer and the second PE film layer are melted during high-temperature forming, the effect of connecting the napping surface layer 30 and the flame-retardant carpet base material layer 10 is achieved, and meanwhile, a good sound insulation effect is achieved; on the other hand, the soundproof adhesive layer 50 is inevitably punctured by the flame-retardant base layer 70 when the flame-retardant base layer 70 is compression-molded.

The soundproof adhesive layer 50 may be adhered to the raised surface layer 30 through a hot pressing process. The thickness of the first PE film layer may be equal to the thickness of the second PE film layer, and the thickness of the PA film layer may be greater than the first PE film layer and the second PE film layer to improve the flame retardancy of the sound-insulating adhesive layer 50. The gram weight of the sound-insulating adhesive layer 50 is 100g/m2-200g/m 2. Illustratively, the grammage of the sound-insulating adhesive layer 50 may be equal to 100g/m2, 150g/m2, 170g/m2, or 200g/m2, etc. In other embodiments, the sound-insulating adhesive layer 50 may also be a single layer of PE film, which may be made by a laminating process or a dusting process.

In some embodiments, the flame retardant bottom layer 70 is a flame retardant foamed PU (Polyurethane) layer. The flame-retardant foamed PU has excellent heat insulation, sound insulation and fire resistance and long service life. The flame-retardant foamed PU body may have a density of 60g/m3 and the flame-retardant base layer 70 has a thickness of 20mm to 30 mm. Illustratively, the thickness of the flame retardant bottom layer 70 may be equal to 20mm, 25mm, 27mm, or 30mm, etc.

Of course, the flame retardant bottom layer 70 is not limited to being made of flame retardant foamed PU material. In other embodiments, the flame retardant lower layer 70 can be made of equal density cotton, standing cotton, or a mixture of EVA (ethylene vinyl acetate) and PU, which have the same flame retardant effect.

Referring to fig. 3, in some embodiments, the flame retardant carpet 100 further includes a flame retardant latex layer 90, the flame retardant latex layer 90 is stacked between the raised surface layer 30 and the sound insulation adhesive layer 50, and the flame retardant latex layer 90 is flame retardant by using phosphorus. The flame-retardant latex layer 90 is equivalent to glue coating at the bottom of the raised surface layer 30, and can be used for shaping fibers of the raised surface layer 30, so that better fixed chemical fibers can be obtained, and the wear resistance is improved.

The flame-retardant latex layer 90 can adopt a phosphorus-based blending flame-retardant or phosphorus-nitrogen-based blending flame-retardant mode, and meets the requirements of relevant regulations at home and abroad. The flame-retardant latex layer 90 may be a SBR (styrene butadiene rubber) flame-retardant latex layer or an EVA flame-retardant latex layer. The gram weight of the flame-retardant latex layer 90 is 50g/m2-100g/m 2. Illustratively, the grammage of the flame retardant latex layer 90 may be equal to 50g/m2, 60g/m2, 80g/m2, or 100g/m2, etc.

After the flame retardant carpet 100 provided in the embodiment of the present application is molded, the performance specifications are shown in the following table.

Table one: performance specifications for flame retardant carpet 100

The flame-retardant carpet 100 provided by the embodiment of the application can meet the flame-retardant requirement in the field of civil aviation, can realize a permanent flame-retardant effect, and also solves the problem that an aviation carpet can only be molded in a plane and cannot be made into a complex structure; meanwhile, the fiber sizes and the matching combination of the flame-retardant PET fiber material and the low-melting-point PET fiber material in the raised surface layer 30 and the flame-retardant carpet base material layer 10 also meet the design requirements of needling effect, high pile, formability, wear resistance, elongation at break and the like.

Referring to fig. 4, the present application also provides a method for manufacturing a flame retardant carpet, which may specifically include the following steps S110 to S140.

Step S110: feeding, opening, mixing, carding, lapping, needling and napping the low-melting-point PET fiber material and the flame-retardant PET fiber material adopting phosphorus flame retardance according to a set proportion to form a napped surface layer.

Step S120: and a sound insulation bonding layer is attached to the bottom surface of the raised surface layer.

Specifically, when the sound-insulating adhesive layer comprises a first PE film layer, a PA film layer and a second PE film layer which are sequentially stacked, the prepared sound-insulating adhesive layer and the napping surface layer can be bonded through a hot-pressing process. When the sound insulation bonding layer is a single-layer PE film, the single-layer PE film can be obtained by film coating on the bottom surface of the raised surface layer.

Step S130: mixing a low-melting-point PET fiber material and a flame-retardant PET fiber material adopting a phosphorus system flame retardant according to a set proportion, carding and lapping to form a flame-retardant carpet base material layer, and compounding the flame-retardant carpet base material layer on the surface of the sound insulation bonding layer, which is far away from the raised surface layer. Specifically, the flame-retardant carpet base material layer, the sound-insulating adhesive layer and the napping surface layer can be compounded together through a compression molding process.

Step S140: and the flame-retardant bottom layer is compounded on the surface of the flame-retardant carpet base material layer, which is far away from the sound insulation adhesive layer.

Specifically, when fire-retardant bottom is fire-retardant foaming PU layer, can form fire-retardant bottom through injection technology on the surface that fire-retardant carpet substrate layer deviates from the adhesive linkage that gives sound insulation, rethread compression molding technology with fire-retardant bottom, fire-retardant carpet substrate layer, the adhesive linkage that gives sound insulation and pile top layer complex together, form fire-retardant carpet.

Referring to fig. 5, in some embodiments, the manufacturing method provided in the embodiments of the present application may specifically include the following steps S210 to S250.

Step S210: feeding, opening, mixing, carding, lapping, needling and napping the low-melting-point PET fiber material and the flame-retardant PET fiber material adopting phosphorus flame retardance according to a set proportion to form a napped surface layer.

Step S220: and gluing the bottom surface of the raised surface layer to form a phosphorus flame-retardant emulsion layer.

Step S230: and a sound insulation bonding layer is attached to the surface of the flame-retardant latex layer, which is far away from the raised surface layer.

Specifically, when the sound insulation adhesive layer comprises a first PE film layer, a PA film layer and a second PE film layer which are sequentially stacked, the prepared sound insulation adhesive layer, the flame-retardant emulsion layer and the napping surface layer can be pressed through a hot pressing process. When the sound insulation bonding layer is a single-layer PE film, the film can be sprayed on the bottom surface of the flame-retardant emulsion layer to obtain the single-layer PE film.

Step S240: mixing a low-melting-point PET fiber material and a flame-retardant PET fiber material adopting a phosphorus system flame retardant according to a set proportion, carding and lapping to form a flame-retardant carpet base material layer, and compounding the flame-retardant carpet base material layer on the surface of the sound insulation bonding layer departing from the flame-retardant emulsion layer.

Step S250: and the flame-retardant bottom layer is compounded on the surface of the flame-retardant carpet base material layer, which is far away from the sound insulation adhesive layer.

The flame retardant carpet and the method for manufacturing the flame retardant carpet provided in the examples of the present application are further described below by specific examples. The following examples are, of course, intended to illustrate the invention and are not intended to limit the scope of the invention.

Example one

The embodiment of the application provides a flame-retardant carpet, including pile surface layer, fire-retardant emulsion layer, the adhesive linkage that gives sound insulation, fire-retardant carpet substrate layer and the fire-retardant bottom of range upon range of arranging in proper order.

The napping surface layer comprises a flame-retardant PET fiber material and a low-melting-point fiber PET material, and the gram weight of the napping surface layer is equal to 400g/m 2. The flame-retardant PET fiber material is characterized in that the fiber number of the flame-retardant PET fiber material is 8D, the fiber length is 76mm, the flame-retardant method adopts a phosphorus copolymerization flame-retardant mode, and the mass percentage of phosphorus element is 0.9%. The low-melting-point PET fiber material has a fiber fineness of 4D and a fiber length of 51 mm. The mass proportion of the flame-retardant PET fiber material in the raised surface layer is 90%, and correspondingly, the mass proportion of the low-melting-point PET fiber material in the raised surface layer is 10%. And mixing the flame-retardant PET fiber material and the low-melting-point PET fiber material, carding, lapping, and finally needling and raising, wherein the height of raised pile after needling and raising is 5 mm.

The flame-retardant latex layer is an SBR flame-retardant latex layer, and the gram weight of the flame-retardant latex layer is 100g/m 2. The flame-retardant method of the flame-retardant latex layer can adopt a phosphorus-series blending flame-retardant or phosphorus-nitrogen-series blending flame-retardant mode. The sound insulation bonding layer comprises a first PE film layer, a PA film layer and a second PE film layer which are arranged in a stacked mode, and the gram weight of the sound insulation bonding layer is 100g/m 2.

The flame-retardant carpet base material layer contains a flame-retardant PET fiber material and a low-melting-point PET fiber material, and the gram weight of the flame-retardant carpet base material layer is 500g/m 2. The fiber fineness of the flame-retardant PET fiber material is 12D, the fiber length is 64mm, the flame-retardant method adopts a phosphorus copolymerization flame-retardant mode, and the phosphorus content in the flame-retardant PET fiber material is 0.9% by mass. The low-melting-point PET fiber material has a fiber fineness of 4D and a fiber length of 51 mm. The weight proportion of the flame-retardant PET fiber material in the flame-retardant carpet base material layer is 80%, and correspondingly, the weight proportion of the low-melting-point PET fiber material in the flame-retardant carpet base material layer is 20%. The flame-retardant PET fiber material and the low-melting-point PET fiber material are mixed, carded, lapped and compounded.

The flame-retardant bottom layer is made of flame-retardant foamed PU, and the flame-retardant method adopts a phosphorus flame-retardant mode, and specifically can be phosphorus copolymerization flame-retardant, phosphorus blending flame-retardant or phosphorus-nitrogen blending flame-retardant. The flame-retardant foamed PU has a bulk density of 60g/m3 and the thickness of the flame-retardant bottom layer ranges from 20mm to 30 mm.

The method for manufacturing the flame retardant carpet may specifically include the following steps 310 to S350.

Step 310: feeding, opening, mixing, carding, lapping, needling and napping a low-melting-point PET fiber material and a flame-retardant PET fiber material adopting a phosphorus flame retardant according to a set proportion to form a napped surface layer.

Step S320: and coating the SBR flame-retardant latex on the bottom surface of the raised surface layer to form a flame-retardant latex layer.

Step S330: and a sound insulation bonding layer is attached to the surface of the flame-retardant latex layer, which is far away from the raised surface layer.

Step S340: the low-melting-point PET fiber material and the flame-retardant PET fiber material adopting the phosphorus flame retardant system are mixed according to a set proportion, then are carded and are lapped to form an even flame-retardant carpet base material layer, and then the flame-retardant carpet base material layer is compounded on the surface of the sound insulation bonding layer deviating from the flame-retardant emulsion layer through a compression molding process.

Step S350: injecting the flame-retardant foaming PU into the flame-retardant bottom layer formed on the surface of the flame-retardant carpet base material layer deviating from the sound-insulation bonding layer, and compounding the flame-retardant bottom layer, the flame-retardant carpet base material layer, the sound-insulation bonding layer, the flame-retardant latex layer and the napping surface layer together by a compression molding process to form the flame-retardant carpet.

Example two

The embodiment of the application provides a fire-retardant carpet, including pile top layer, the adhesive linkage that gives sound insulation, fire-retardant carpet substrate layer and the fire-retardant bottom of stacking gradually arranging.

The napping surface layer comprises a flame-retardant PET fiber material and a low-melting-point PET fiber material, and the gram weight of the napping surface layer is 400g/m 2. The flame-retardant PET fiber material is characterized in that the fiber number of the flame-retardant PET fiber material is 8D, the fiber length is 76mm, the flame-retardant method adopts a phosphorus copolymerization flame-retardant mode, and the mass percentage of phosphorus element is 0.9%. The low-melting-point PET fiber material has a fiber fineness of 4D and a fiber length of 51 mm. The weight proportion of the flame-retardant PET fiber material in the raised surface layer is 90%, and correspondingly, the weight proportion of the low-melting-point PET fiber material in the raised surface layer is 10%. And (3) mixing the flame-retardant PET fiber material and the low-melting-point PET fiber material, carding, lapping, and finally needling and napping, wherein the napping height after needling and napping is 5 mm.

The sound insulation adhesive layer comprises a first PE film layer, a PA film layer and a second PE film layer which are arranged in a stacked mode, and the gram weight of the sound insulation adhesive layer is 150g/m 2.

The flame-retardant carpet base material layer contains a flame-retardant PET fiber material and a low-melting-point PET fiber material, and the gram weight of the flame-retardant carpet base material layer is 500g/m 2. The flame-retardant PET fiber material has the fiber fineness of 12D and the fiber length of 64mm, the flame-retardant method adopts a phosphorus copolymerization flame-retardant mode, and the phosphorus content in the flame-retardant PET fiber material is 0.9% by mass. The low-melting-point PET fiber material had a fiber fineness of 4D and a fiber length of 51 mm. The weight proportion of the flame-retardant PET fiber material in the flame-retardant carpet base material layer is 80%, and correspondingly, the weight proportion of the low-melting-point PET fiber material in the flame-retardant carpet base material layer is 20%. The flame-retardant PET fiber material and the low-melting-point PET fiber material are mixed, carded, lapped and compounded.

The flame-retardant bottom layer is made of flame-retardant foamed PU, and the flame-retardant method adopts a phosphorus flame-retardant mode, and specifically can be phosphorus copolymerization flame-retardant, phosphorus blending flame-retardant or phosphorus-nitrogen blending flame-retardant. The bulk density of the flame-retardant foamed PU is 60g/m3, and the thickness of the flame-retardant bottom layer ranges from 20mm to 30 mm.

The method for manufacturing the flame retardant carpet may specifically include the following steps 410 to 440.

Step 410: feeding, opening, mixing, carding, lapping, needling and napping a low-melting-point PET fiber material and a flame-retardant PET fiber material adopting a phosphorus flame retardant according to a set proportion to form a napped surface layer.

Step S420: and a sound insulation bonding layer is attached to the bottom surface of the raised surface layer.

Step S430: mixing a low-melting-point PET fiber material and a flame-retardant PET fiber material adopting a phosphorus system flame retardant according to a set proportion, carding and lapping to form a flame-retardant carpet base material layer, and compounding the flame-retardant carpet base material layer on the surface of the sound insulation bonding layer, which is far away from the napping surface layer, through a compression molding process.

Step S440: injecting the flame-retardant foaming PU into the flame-retardant bottom layer formed on the surface of the flame-retardant carpet base material layer deviating from the sound-insulation bonding layer, and compounding the flame-retardant bottom layer, the flame-retardant carpet base material layer, the sound-insulation bonding layer, the flame-retardant latex layer and the napping surface layer together by a compression molding process to form the flame-retardant carpet.

EXAMPLE III

The third embodiment of the application provides a fire-retardant carpet, including pile surface layer, fire-retardant emulsion layer, the adhesive linkage that gives sound insulation, fire-retardant carpet substrate layer and the fire-retardant bottom of stacking gradually arranging.

The napping surface layer comprises a flame-retardant PET fiber material and a low-melting-point PET fiber material, and the gram weight of the napping surface layer is 350g/m 2. The flame-retardant PET fiber material is characterized in that the fiber number of the flame-retardant PET fiber material is 6D, the fiber length is 64mm, the flame-retardant method adopts a phosphorus copolymerization flame-retardant mode, and the mass percentage of phosphorus in the flame-retardant PET fiber material is 0.9%. The fineness of the low-melting-point PET fiber material is 4D, and the fiber length is 51 mm. The weight proportion of the flame-retardant PET fiber material in the raised surface layer is 90%, and correspondingly, the weight proportion of the low-melting-point PET fiber material in the raised surface layer is 10%. And (3) mixing the flame-retardant PET fiber material and the low-melting-point PET fiber material, carding, lapping, and finally needling and napping, wherein the napping height after needling and napping is 4 mm.

The flame-retardant latex layer is an SBR flame-retardant latex layer, the gram weight of the flame-retardant latex layer is 50g/m2, and the flame-retardant method adopts a phosphorus-based blending flame-retardant or phosphorus-nitrogen-based blending flame-retardant mode. The sound insulation adhesive layer comprises a first PE film layer, a PA film layer and a second PE film layer which are arranged in a stacked mode, and the gram weight of the sound insulation adhesive layer is 150g/m 2.

The flame-retardant carpet base material layer contains a flame-retardant PET fiber material and a low-melting-point PET fiber material, and the gram weight of the flame-retardant carpet base material layer is 400g/m 2. The flame-retardant PET fiber material has the fiber fineness of 15D and the fiber length of 64mm, the flame-retardant method adopts a phosphorus copolymerization flame-retardant mode, and the phosphorus content in the flame-retardant PET fiber material is 0.9% by mass. The fineness of the low-melting-point PET fiber material is 4D, and the fiber length is 51 mm. The weight proportion of the flame-retardant PET fiber material in the flame-retardant carpet base material layer is 70%, and correspondingly, the weight proportion of the low-melting-point PET fiber material in the flame-retardant carpet base material layer is 30%. The flame-retardant PET fiber material and the low-melting-point PET fiber material are mixed, carded, lapped and compounded.

The flame-retardant bottom layer is made of flame-retardant foamed PU, the flame-retardant method adopts phosphorus flame retardance, such as phosphorus copolymerization flame retardance, phosphorus blending flame retardance or phosphorus-nitrogen blending flame retardance, the bulk density of the flame-retardant foamed PU is 60g/m3, and the thickness of the flame-retardant bottom layer is 20mm-30 mm.

The method for manufacturing the flame retardant carpet may specifically include the following steps 510 to S550.

Step 510: feeding, opening, mixing, carding, lapping, needling and napping a low-melting-point PET fiber material and a flame-retardant PET fiber material adopting a phosphorus flame retardant according to a set proportion to form a napped surface layer.

Step S520: and coating the SBR flame-retardant latex on the bottom surface of the raised surface layer to form a flame-retardant latex layer.

Step S530: and a sound insulation bonding layer is attached to the surface of the flame-retardant latex layer, which is far away from the raised surface layer.

Step S540: mixing a low-melting-point PET fiber material and a flame-retardant PET fiber material adopting a phosphorus system flame retardant according to a set proportion, carding and lapping to form an even flame-retardant carpet base material layer, and compounding the flame-retardant carpet base material layer on the surface of the sound insulation adhesive layer deviating from the flame-retardant latex layer through a compression molding process.

Step S550: injecting the flame-retardant foaming PU into the flame-retardant bottom layer formed on the surface of the flame-retardant carpet base material layer deviating from the sound-insulation bonding layer, and compounding the flame-retardant bottom layer, the flame-retardant carpet base material layer, the sound-insulation bonding layer, the flame-retardant latex layer and the napping surface layer together by a compression molding process to form the flame-retardant carpet.

Example four

The fourth embodiment of the application provides a fire-retardant carpet, including pile top layer, the adhesive linkage that gives sound insulation, fire-retardant carpet substrate layer and the fire-retardant bottom of range upon range of arranging in proper order.

The napping surface layer comprises a flame-retardant PET fiber material and a low-melting-point PET fiber material, and the gram weight of the napping surface layer is 350g/m 2. The flame-retardant PET fiber material is characterized in that the fiber number of the flame-retardant PET fiber material is 6D, the fiber length is 64mm, the flame-retardant method adopts a phosphorus copolymerization flame-retardant mode, and the mass percentage of phosphorus in the flame-retardant PET fiber material is 0.9%. The low-melting-point PET fiber material has a fiber fineness of 4D and a fiber length of 51 mm. The weight proportion of the flame-retardant PET fiber material in the raised surface layer is 90%, and correspondingly, the weight proportion of the low-melting-point PET fiber material in the raised surface layer is 10%. And (3) mixing the flame-retardant PET fiber material and the low-melting-point PET fiber material, carding, lapping, and finally needling and napping, wherein the napping height after needling and napping is 4 mm.

The flame-retardant carpet base material layer comprises a flame-retardant PET fiber material, a low-melting-point PET fiber material and a low-melting-point flame-retardant PET fiber material. The gram weight of the flame-retardant carpet base material layer is 400g/m 2. The flame-retardant PET fiber material has the fiber fineness of 15D and the fiber length of 64mm, the flame-retardant method adopts a phosphorus copolymerization flame-retardant mode, and the phosphorus content in the flame-retardant PET fiber material is 0.9% by mass. The low-melting-point PET fiber material has a fiber fineness of 4D and a fiber length of 51 mm. The weight proportion of the flame-retardant PET fiber material in the flame-retardant carpet base material layer is 70%, the weight proportion of the low-melting-point flame-retardant PET fiber material in the flame-retardant carpet base material layer is 15%, and the weight proportion of the low-melting-point PET fiber material in the flame-retardant carpet base material layer is 15%. And the flame-retardant PET fiber material, the low-melting-point flame-retardant PET fiber material and the low-melting-point PET fiber material are mixed, carded, lapped and compounded.

The method for manufacturing the flame retardant carpet may specifically include the following steps 610 to S640.

Step 610: feeding, opening, mixing, carding, lapping, needling and napping a low-melting-point PET fiber material and a flame-retardant PET fiber material adopting a phosphorus flame retardant according to a set proportion to form a napped surface layer.

Step S620: and a sound insulation bonding layer is attached to the bottom surface of the raised surface layer.

Step S630: mixing a low-melting-point PET fiber material, a phosphorus-based flame-retardant low-melting-point flame-retardant PET fiber material and a phosphorus-based flame-retardant PET fiber material according to a set proportion, carding and lapping to form a flame-retardant carpet base material layer, and compounding the flame-retardant carpet base material layer on the surface of the sound-insulation bonding layer, which is far away from the napping surface layer, by a compression molding process.

Step S640: injecting the flame-retardant foaming PU into the flame-retardant bottom layer formed on the surface of the flame-retardant carpet base material layer deviating from the sound-insulation bonding layer, and compounding the flame-retardant bottom layer, the flame-retardant carpet base material layer, the sound-insulation bonding layer, the flame-retardant latex layer and the napping surface layer together by a compression molding process to form the flame-retardant carpet.

EXAMPLE five

The fifth embodiment of the application provides a flame-retardant carpet, which comprises a napping surface layer, a sound insulation bonding layer, a flame-retardant carpet base material layer and a flame-retardant bottom layer which are sequentially stacked and arranged.

The napping surface layer comprises a flame-retardant PET fiber material and a low-melting-point PET fiber material, and the gram weight of the napping surface layer is 350g/m 2. The flame-retardant PET fiber material is characterized in that the fiber number of the flame-retardant PET fiber material is 6D, the fiber length is 64mm, the flame-retardant method adopts a phosphorus copolymerization flame-retardant mode, and the mass percentage of phosphorus in the flame-retardant PET fiber material is 0.9%. The low-melting-point PET fiber material had a fiber fineness of 4D and a fiber length of 51 mm. The weight proportion of the flame-retardant PET fiber material in the raised surface layer is 90%, and correspondingly, the weight proportion of the low-melting-point PET fiber material in the raised surface layer is 10%. And (3) mixing the flame-retardant PET fiber material and the low-melting-point PET fiber material, carding, lapping, and finally needling and napping, wherein the napping height after needling and napping is 4 mm.

The flame-retardant carpet base material layer contains a flame-retardant PET fiber material and a low-melting-point flame-retardant PET fiber material, and the gram weight of the flame-retardant carpet base material layer is 400g/m 2. The flame-retardant PET fiber material has the fiber fineness of 15D and the fiber length of 64mm, the flame-retardant method adopts a phosphorus copolymerization flame-retardant mode, and the phosphorus content in the flame-retardant PET fiber material is 0.9% by mass. The fiber fineness of the low-melting-point flame-retardant PET fiber material is 4D, and the fiber length is 51 mm. The weight proportion of the flame-retardant PET fiber material in the flame-retardant carpet base material layer is 70%, and the weight proportion of the low-melting-point flame-retardant PET fiber material in the flame-retardant carpet base material layer is 30%. The flame-retardant PET fiber material and the low-melting-point flame-retardant PET fiber material are mixed, carded, lapped and compounded.

The method for manufacturing the flame retardant carpet may specifically include the following steps 710 to 740.

Step 710: feeding, opening, mixing, carding, lapping, needling and napping a low-melting-point PET fiber material and a flame-retardant PET fiber material adopting a phosphorus flame retardant according to a set proportion to form a napped surface layer.

Step S720: and a sound insulation bonding layer is attached to the bottom surface of the raised surface layer.

Step S730: mixing a phosphorus flame-retardant low-melting-point flame-retardant PET fiber material and a phosphorus flame-retardant PET fiber material according to a set proportion, carding and lapping to form a flame-retardant carpet base material layer, and compounding the flame-retardant carpet base material layer on the surface of the sound insulation bonding layer, which is far away from the napping surface layer, through a compression molding process.

Step S740: injecting the flame-retardant foaming PU into the flame-retardant bottom layer formed on the surface of the flame-retardant carpet base material layer deviating from the sound-insulation bonding layer, and compounding the flame-retardant bottom layer, the flame-retardant carpet base material layer, the sound-insulation bonding layer, the flame-retardant latex layer and the napping surface layer together by a compression molding process to form the flame-retardant carpet.

Example six

The embodiment of the application provides an inflaming retarding carpet, including pile-up top layer, fire-retardant emulsion layer, the adhesive linkage that gives sound insulation, fire-retardant carpet substrate layer and the fire-retardant bottom of stacking gradually arranging.

The napping surface layer comprises a flame-retardant PET fiber material and a low-melting-point fiber PET material, and the gram weight of the napping surface layer is equal to 500g/m 2. The flame-retardant PET fiber material is characterized in that the fiber number of the flame-retardant PET fiber material is 6D, the fiber length is 64mm, the flame-retardant method adopts a phosphorus copolymerization flame-retardant mode, and the mass percentage of phosphorus is 0.9%. The low-melting-point PET fiber material has a fiber fineness of 4D and a fiber length of 51 mm. The mass proportion of the flame-retardant PET fiber material in the napped surface layer is 74%, and correspondingly, the mass proportion of the low-melting-point PET fiber material in the napped surface layer is 26%. And mixing the flame-retardant PET fiber material and the low-melting-point PET fiber material, carding, lapping, and finally needling and napping, wherein the napping height after needling and napping is 4 mm.

The flame-retardant latex layer is an EVA flame-retardant latex layer, and the gram weight of the flame-retardant latex layer is 100g/m 2. The flame-retardant method of the flame-retardant emulsion layer adopts a phosphorus-nitrogen system blending flame-retardant mode. The sound insulation bonding layer comprises a first PE film layer, a PA film layer and a second PE film layer which are arranged in a stacked mode, and the gram weight of the sound insulation bonding layer is 100g/m 2.

The flame-retardant carpet base material layer contains a flame-retardant PET fiber material and a low-melting-point PET fiber material, and the gram weight of the flame-retardant carpet base material layer is 500g/m 2. The flame-retardant PET fiber material is characterized in that the fiber fineness of the flame-retardant PET fiber material is 12D, the fiber length is 64mm, the flame-retardant method adopts a phosphorus copolymerization flame-retardant mode, and the phosphorus content in the flame-retardant PET fiber material is 0.85% by mass. The low-melting-point PET fiber material has a fiber fineness of 4D and a fiber length of 51 mm. The weight proportion of the flame-retardant PET fiber material in the flame-retardant carpet base material layer is 70%, and correspondingly, the weight proportion of the low-melting-point PET fiber material in the flame-retardant carpet base material layer is 30%. The flame-retardant PET fiber material and the low-melting-point PET fiber material are mixed, carded, lapped and compounded.

The flame-retardant bottom layer is made of flame-retardant foamed PU, and the flame-retardant method adopts a phosphorus flame-retardant mode, and specifically can be phosphorus copolymerization flame-retardant, phosphorus blending flame-retardant or phosphorus-nitrogen blending flame-retardant. The flame-retardant foamed PU had a bulk density of 60g/m3 and the thickness of the flame-retardant base layer was 25 mm.

The sixth embodiment improves the mass ratio of the low-melting-point PET fiber material in the napping surface layer and the flame-retardant carpet substrate layer, reduces the mass percentage of phosphorus in the flame-retardant PET fiber material, and limits the fiber fineness, the fiber length, the gram weight and the napping height so as to improve the moldability of the flame-retardant carpet.

EXAMPLE seven

The seventh embodiment of the application provides a fire-retardant carpet, including pile surface layer, fire-retardant emulsion layer, the adhesive linkage that gives sound insulation, fire-retardant carpet substrate layer and the fire-retardant bottom of stacking gradually arranging.

The napping surface layer comprises a flame-retardant PET fiber material and a low-melting-point fiber PET material, and the gram weight of the napping surface layer is equal to 450g/m 2. The flame-retardant PET fiber material is characterized in that the fiber number of the flame-retardant PET fiber material is 5D, the fiber length is 76mm, the flame-retardant method adopts a phosphorus copolymerization flame-retardant mode, and the mass percentage of phosphorus is 0.98%. The fiber fineness of the low-melting-point PET fiber material is 4D, and the fiber length is 90 mm. The mass proportion of the flame-retardant PET fiber material in the napped surface layer is 93%, and correspondingly, the mass proportion of the low-melting-point PET fiber material in the napped surface layer is 7%. And mixing the flame-retardant PET fiber material and the low-melting-point PET fiber material, carding, lapping, and finally needling and napping, wherein the napping height after needling and napping is 4 mm.

The flame-retardant carpet base material layer contains a flame-retardant PET fiber material and a low-melting-point PET fiber material, and the gram weight of the flame-retardant carpet base material layer is 500g/m 2. The flame-retardant PET fiber material is characterized in that the fiber number of the flame-retardant PET fiber material is 12D, the fiber length is 64mm, the flame-retardant method adopts a phosphorus copolymerization flame-retardant mode, and the phosphorus content in the flame-retardant PET fiber material is 0.97% by mass. The low-melting-point PET fiber material has a fiber fineness of 4D and a fiber length of 51 mm. The weight proportion of the flame-retardant PET fiber material in the flame-retardant carpet base material layer is 80%, and the weight proportion of the low-melting-point PET fiber material in the flame-retardant carpet base material layer is 20%. The flame-retardant PET fiber material and the low-melting-point PET fiber material are mixed, carded, lapped and compounded.

The embodiment seventhly improves the mass ratio of the flame-retardant PET fiber material in the napping surface layer and the flame-retardant carpet base material layer, improves the mass percentage of phosphorus content in the flame-retardant PET fiber material, and limits the fiber fineness, the fiber length, the gram weight and the napping height so as to improve the flame retardance of the flame-retardant carpet.

In the first to seventh embodiments, the fourth embodiment has the best overall effects of flame retardant effect, smoke density and toxic gas amount, needle raising effect, breaking strength and elongation, weight, formability, VOC, odor, cost, and the like.

Although the present application has been described with reference to a preferred embodiment, it should be understood that various changes, substitutions and alterations can be made herein without departing from the spirit and scope of the invention as defined by the appended claims.

Claims

1. The flame-retardant carpet base material layer is characterized by at least comprising a flame-retardant PET fiber material and a low-melting-point PET fiber material, wherein the flame-retardant PET fiber material is flame-retardant by adopting a phosphorus system, the mass percentage of the flame-retardant PET fiber material is 60-80%, and the mass percentage of the low-melting-point PET fiber material is 20-30%.

2. The flame-retardant carpet base material layer of claim 1, wherein the flame-retardant PET fiber material contains phosphorus element in an amount of 0.8-1% by mass.

3. The flame retardant carpet substrate layer of claim 1 wherein the flame retardant PET fiber material has a limiting oxygen index of greater than 31.

4. The flame retardant carpet substrate layer of claim 1 wherein the low melting point PET fiber material has a melting point of 115 ℃ to 130 ℃.

5. The flame retardant carpet substrate layer of claim 1 further comprising a low melting point flame retardant PET fiber material that is flame retardant with a phosphorous system.

6. The flame retardant carpet substrate layer of claim 1, wherein the low melting point PET fiber material is partially or completely a low melting point flame retardant PET fiber material adopting a phosphorus flame retardant.

7. The flame-retardant carpet substrate layer according to claim 1, wherein the flame-retardant PET fiber material has a fiber fineness of 8D-15D and a fiber length of 51mm-90 mm; the fiber fineness of the low-melting-point PET fiber material is 4D, and the fiber length is 51-90 mm.

8. The flame retardant carpet substrate layer of claim 1, wherein the flame retardant carpet substrate layer has a thickness of 3mm to 5 mm.

9. The flame retardant carpet substrate layer of claim 1 wherein the grammage of the flame retardant carpet substrate layer is 400g/m²-600g/m²。

10. A flame retardant carpet comprising a pile top layer, a sound-insulating adhesive layer, a flame retardant base layer and the flame retardant carpet substrate layer according to any one of claims 1 to 9, wherein the pile top layer, the sound-insulating adhesive layer, the flame retardant carpet substrate layer and the flame retardant base layer are sequentially stacked.