WO2022199642A1 - 一种耐火焰毡 - Google Patents

一种耐火焰毡 Download PDF

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Publication number
WO2022199642A1
WO2022199642A1 PCT/CN2022/082631 CN2022082631W WO2022199642A1 WO 2022199642 A1 WO2022199642 A1 WO 2022199642A1 CN 2022082631 W CN2022082631 W CN 2022082631W WO 2022199642 A1 WO2022199642 A1 WO 2022199642A1
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WIPO (PCT)
Prior art keywords
flame
resistant
fibers
layer
fire
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PCT/CN2022/082631
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English (en)
French (fr)
Inventor
武庭轩
刘同娟
梶山宏史
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东丽纤维研究所（中国）有限公司
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Priority to CN202280009675.5A priority Critical patent/CN116711132A/zh
Publication of WO2022199642A1 publication Critical patent/WO2022199642A1/zh

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B19/00—Layered products comprising a layer of natural mineral fibres or particles, e.g. asbestos, mica
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B29/00—Layered products comprising a layer of paper or cardboard
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M10/00—Secondary cells; Manufacture thereof
    • H01M10/60—Heating or cooling; Temperature control
    • H01M10/65—Means for temperature control structurally associated with the cells
    • H01M10/658—Means for temperature control structurally associated with the cells by thermal insulation or shielding

Definitions

  • the present invention relates to a flame-resistant felt.
  • the thermal insulation and fireproof material wrapped outside the battery is generally formed of multi-layer composite mica board or aerogel filling material, and each layer of the mica board is made of small sheets It is bonded by silicon-based adhesives, and the layers are also bonded by adhesives.
  • a thermal insulation and fireproof material with a thickness of 3 to 5 mm is prepared. Although this material has excellent flame retardant effect, its The strength and hardness are poor, the density is very large, the weight is also large, and the mechanical properties are not good.
  • the filling material using aerogel although it is a flexible material, can withstand shock compression, but because the aerogel is filled later, its density is extremely low, so a large volume is required to obtain a better flame retardant effect. , it will also cause difficulties in the design of other components in the car.
  • Chinese patent CN202871380U discloses a special belt for high flame retardant engineering.
  • the high temperature resistant layer of the material adopts an inorganic mineral layer
  • the inorganic mineral is a particle accumulation
  • the layers contain a large amount of Adhesives, when burned by a flame of more than 1000 degrees, the adhesive and organic flame retardant fabric will quickly fail, resulting in the leakage of granular inorganic minerals, which will cause the metal wires in the cable to be directly heated by the flame.
  • published patent WO2021/000927A1 discloses a fireproof material containing a heat insulating layer and a heat absorbing layer, and the heat insulating layer of the material is formed of a porous material with aerogel powder attached. , can not be used as a flexible material, molding is very difficult. In addition, because the aerogel is not powdery and does not have hydrophilicity, it will cause powder loss and difficulty in bonding during actual use. This material cannot be applied to the upper cover of the battery to block flames.
  • An object of the present invention is to provide a flame-resistant felt with a long flame blocking time, excellent electrical insulating properties, and light weight.
  • the flame-resistant felt of the present invention includes a three-layer composite structure, a fire-resisting layer on the upper and lower surfaces, and a middle barrier layer, and the barrier layer is composed of an inorganic sheet-like material with a melting temperature above 1000 ° C, so The bulk density of the flame-resistant felt is 1200-2300 kg/m 3 .
  • the thickness retention rate of the flame-resistant felt is preferably 40% or more after burning with a butane spray gun at 1200° C. for 5 minutes.
  • the remaining weight ratio of the barrier layer is preferably 70 to 100%.
  • the above-mentioned fire-resistant layer is preferably a fabric or non-woven fabric composed of thermosetting fibers with a limiting oxygen index of 25% or more and thermoplastic fibers with a limiting oxygen index of 25% or more.
  • the content rate of the said thermosetting fiber in a fire-resistant layer is 20-80%.
  • thermosetting fibers are preferably pre-oxidized fibers, phenolic fibers, flame-retardant modified viscose fibers or meta-aramid fibers.
  • the thermoplastic fiber B is preferably selected from the group consisting of anisotropic molten polyester, flame-retardant poly(alkylene terephthalate), flame-retardant poly(acrylonitrile-butadiene-styrene), flame-retardant poly(alkylene terephthalate), Sulfones, poly(ether-ether-ketone), poly(ether-ketone-ketone), polyethersulfone, polyarylate, polyphenylsulfone, polyetherimide, polyamideimide, and mixtures thereof Fiber formed from resin.
  • the above-mentioned inorganic sheet-like material is preferably mica, glass fiber mat, ceramic or quartz.
  • the breakdown voltage of the flame-resistant felt of the present invention is preferably 3000-5000V.
  • the flame-resistant felt of the present invention can directly contact open flames up to 1200° C., and has the characteristics of excellent electrical insulation performance and long flame blocking time.
  • the flame-resistant felt of the present invention compared with inorganic materials of the same performance, it also has the advantage of light weight.
  • Figure 1 is a schematic diagram of the flame-resistant felt of the present invention, in which A is a fire-resistant layer, B is a barrier layer, wherein a is a thermosetting fiber, and b is a thermoplastic fiber.
  • the flame-resistant felt of the present invention comprises a three-layer composite structure, a fire-resisting layer on the upper and lower surfaces, and a middle barrier layer.
  • the barrier layer is composed of an inorganic sheet-like material with a melting temperature above 1000° C.
  • the volume density of the flame-resistant felt is 1200 ⁇ 2300kg/m 3 .
  • the fire-fighting layer here refers to the layer that is distributed on the upper and lower surfaces of the composite material and is directly exposed to the air. When combustion or high temperature occurs, it can first come into contact with the flame or high temperature.
  • the barrier layer here refers to the middle part of the composite material.
  • the barrier layer can block the flame due to its ultra-high temperature resistance, and also has a certain
  • the thermal insulation performance of the fire-resistant layer on the side that is not in direct contact with the flame maintains a certain shape.
  • the upper and lower surface fire layers and the middle barrier layer must limit the position of each layer. If the flame-resistant felt is only a double-layer structure, that is, a fire layer and a barrier layer, since the barrier layer is composed of inorganic sheet materials, During physical-mechanical compounding, if there is no interlayer protection of two fire-retardant layers, it is easy to cause damage to the barrier layer, and the damaged inorganic materials will fall from the fire-resistant layer.
  • the barrier layer constituting the flame-resistant felt of the present invention is composed of an inorganic sheet-like material with a melting temperature above 1000° C.
  • the melting temperature refers to the temperature at which the substance melts, and melting refers to the increase of the thermal kinetic energy of the molecules when the temperature increases. , resulting in the destruction of crystallization, the process of changing the material from the crystalline phase to the liquid phase.
  • the melting temperature here refers to the temperature at which a solid is transformed from a solid state to a liquid state.
  • the melting temperature of the inorganic sheet-like material in the barrier layer is above 1000°C, preferably 1200-1800°C.
  • the barrier layer of the present invention is composed of inorganic materials, and if the barrier layer is made of organic materials, it has poor high temperature resistance performance.
  • the inorganic material here refers to a compound material that does not contain carbon atoms except for carbonates and carbon oxides.
  • the inorganic sheet-like material is a cuboid-shaped material with a thickness ranging from 0.5 to 1 mm, and a length and width at least 10 times or more of the thickness.
  • the density of the inorganic sheet-like material of the present invention is higher than that of the polymer material, such as mica, glass fiber or basalt fiber. Therefore, as the thickness of the inorganic sheet-like material increases, its quality will also increase.
  • the inorganic sheet-like material is too thick , not only the flexibility becomes poor, but also affects the overall lightweight of the flame-resistant felt.
  • the thickness of the inorganic sheet-like material is too thick, it is difficult for the thermal insulation layer made of the inorganic sheet-like material to be combined with the fire-resistant layer, so that it is difficult to further prepare an integral molding material; when the thickness of the inorganic sheet-like material is too thin , the barrier layer after the lamination process will be damaged, and the barrier layer cannot play the role of blocking the flame.
  • the bulk density of the flame-resistant felt of the present invention is related to the upper and lower surfaces of the fire-resistant layer and the barrier layer, the fire-resistant layer is formed by a fiber structure, the bulk density of the fiber structure is generally less than 900kg/m 3 , and the barrier layer is made of inorganic sheet-like materials. Material formation, the bulk density of the inorganic sheet material is generally greater than 2500KG/m 3 .
  • the size of the flame-resistant felt is certain, its bulk density is related to the ratio of the barrier layer and the fire-resistant layer.
  • the bulk density also refers to the apparent density, that is, the ratio of the mass of the material to the apparent volume.
  • the density of the barrier layer should be greater than the density of the fire-resistant layer.
  • the bulk density of the flame-resistant felt is greater than 2300kg/ m3 , that is, when the thickness ratio of the barrier layer in the entire flame-resistant felt is greater than 90%, it indicates the proportion of the barrier layer. If it is too large, that is, the content of inorganic sheet-like materials is too large. Although the flame blocking ability will become stronger, the flame blocking time will also become longer, but if the blocking layer is too thick, the overall flame-resistant felt will be too heavy, which is not conducive to the battery.
  • the increase in energy density also makes it difficult to achieve lightweight; if the bulk density of the flame-resistant felt is less than 1200kg/ m3 , that is, when the thickness ratio of the barrier layer in the entire flame-resistant felt is less than 20%, it means that the barrier If the proportion of the layer is too small, that is, the content of the inorganic flake material is too small, the thickness of the relative fire-attacking layer will increase, and the overall flame-blocking ability will decrease when it is burned by the flame, resulting in the occurrence of danger. Considering the flame blocking time and the weight reduction of the felt, the bulk density of the flame-resistant felt of the present invention is preferably 1200-1800 kg/m 3 .
  • the proportion of the above-mentioned barrier layer in the entire flame-resistant felt is preferably 30 to 90% by weight. If the proportion of the barrier layer is too large, the content of the inorganic sheet-like material is too large, although the flame-blocking ability becomes stronger, the flame-blocking ability is stronger.
  • the time will also be longer, but if the barrier layer is too thick, the overall weight of the flame-resistant felt will be too large, which is not conducive to the improvement of battery energy density, and also causes substantial difficulties in achieving lightweight; if the barrier layer occupies If the ratio is too small, that is, the content of the inorganic flake material is too small, the thickness of the relative fire-attacking layer will increase, and the overall flame-blocking ability will decrease when it is burned by the flame, resulting in the occurrence of danger. In consideration of the time for blocking the flame and the weight reduction of the felt, the proportion of the barrier layer in the entire flame-resistant felt is more preferably 30 to 80% by weight.
  • the thickness retention rate of the flame-resistant felt is preferably more than 40%.
  • the thickness of the burned part accounts for the percentage of the thickness of the part before burning, and the thickness retention rate is an important indicator to measure the fireproof and heat insulation performance of the flame-resistant felt.
  • the thickness retention rate of the flame-resistant felt of the present invention is actually achieved by the thickness ratio of the fire-resistant layer and the barrier layer.
  • the thickness of each layer is not limited here.
  • the thickness of the fire-resistant layer on the upper surface and the thickness of the fire-resistant layer on the lower surface can be The same or different.
  • the thickness retention rate of the flame-resistant felt can reach more than 40%.
  • the flame-resistant felt has a very eccentric structure, that is, when the thickness ratio of the fire-resistant layers on both sides is less than 50%, in order to make the thickness retention rate of the flame-resistant felt more than 40%, the thinner side of the fire-resistant layer should be used.
  • the flame has less thickness loss, and the overall thickness retention rate can be maintained at more than 40%. Therefore, in the case of extreme eccentricity, it is best to use a thinner layer of fire-resistant layer to preferentially contact the flame. If the thicker side is in direct contact with the flame, the thickness loss of the three-layer composite will be large, and the thickness retention rate of the flame-resistant felt will be less than 40%. Considering that the flame-resistant felt may not be able to limit whether the flame-resistant thin layer or the thick layer contacts the flame, the thickness ratio of the upper and lower fire-resistant layers of the present invention is preferably 56-100%.
  • the thickness ratio of the two fire layers refers to the thickness ratio of the thin layer to the thick layer, regardless of its specific location. For example: when the thickness of the fireproof layer is 0.4mm and 0.6mm respectively, the thickness ratio of the fireproof layer of the flame-resistant felt is 2/3, that is, 66.7%.
  • the fire-proof flame-shielding material is attached to the cover plate on the battery, so as to achieve the effect of heat insulation and fire prevention.
  • the lithium-ion battery is thermally out of control, causing the temperature to catch fire or even explode, the temperature in the battery will rise to more than 1000 degrees in one minute. other flames above degrees.
  • a nickel-cobalt-manganese ternary lithium battery or a nickel-cobalt-aluminum ternary lithium battery simply uses a liquid electrolyte, although the energy density of the battery can be increased when the nickel content in the positive electrode material is increased, it will affect the stability of the material and eventually lead to The overall stability and safety of the battery decreases.
  • the flame-resistant felt of the present invention can provide good flame blocking and high temperature effects. Combining the felt of the present invention with a lithium battery on an automobile can effectively block the flame, prevent the flame from burning on the cover, and the flame will not directly Burn the passenger compartment.
  • the thermal performance that is, the thermal resistance
  • the thermal resistance is only related to the thickness of the material. The thicker the thickness of the material, the longer it takes for the heat to transfer from one end of the material to the other The longer the temperature is, the longer it takes to heat up. In the event of thermal runaway, the higher the protection ability of the flame-resistant felt to the cabin; The shorter the time required, the less the flame-resistant felt will protect the cabin in the event of thermal runaway.
  • the thickness retention rate of the flame-resistant felt of the present invention is more preferably 40-60%, more preferably 50-60% after burning with a butane spray gun for 5 minutes .
  • the remaining weight ratio of the barrier layer is preferably 70 to 100%.
  • the inorganic sheet material is affected by high temperature, some physical and chemical decomposition will occur, resulting in a decrease in the thickness and quality of the barrier layer.
  • the melting temperature of some inorganic materials does not reach 1200 °C, such as asbestos mineral fibers, when encountering high temperatures, they will slowly melt and flow out, and the mass of the barrier layer will be lost, so the remaining weight ratio of the barrier layer will be relatively low. Therefore, the melting temperature of the inorganic sheet-like material is preferably 1200°C or higher.
  • the remaining weight ratio of the barrier layer is more preferably 80-100%.
  • the fireproof layer of the present invention is preferably a fabric or non-woven fabric composed of thermosetting fibers with a limiting oxygen index of more than 25% and thermoplastic fibers with a limiting oxygen index of more than 25%.
  • thermosetting fiber refers to a fibrous material that decomposes or degrades without softening and melting after being heated.
  • the diameter of the material is less than 100 ⁇ m and the aspect ratio is greater than 500 ⁇ m, such as cotton fiber, flax fiber, ramie fiber, chemical fiber in natural fibers. Viscose fiber, meta-aramid fiber, pre-oxidized fiber and carbon fiber in the.
  • Thermoplastic fiber refers to a fibrous material in which the fiber is softened and melted into a liquid state after being heated, and then decomposed.
  • the limiting oxygen index of the thermosetting fiber and the thermoplastic fiber of the present invention is both above 25%.
  • the limiting oxygen index refers to the volume percentage of the minimum amount of oxygen required by a polymer in a mixed gas of oxygen and nitrogen to maintain the combustion of a substance, and is an indicator to characterize the flammability of a material. The higher the limiting oxygen index, the more difficult it is to burn; the lower the limiting oxygen index, the easier it is to burn and produce flames, so that the effect of fire prevention and flame shielding cannot be achieved. Therefore, the limiting oxygen index of the thermosetting fiber is preferably 25% or more, and more preferably 30% or more. The limiting oxygen index of the thermoplastic fiber is preferably 25% or more, and more preferably 30% or more.
  • the above-mentioned fireproof layer is preferably a woven fabric or a non-woven fabric.
  • the thermosetting fibers and thermoplastic fibers used can be in the form of filaments or yarns.
  • the form is a yarn, considering the spinning process and the difficulty of blending with other fibers, the fibers
  • the length is preferably 30 to 65 mm, more preferably 38 to 51 mm, and the fiber diameter is preferably 1 to 6 dtex.
  • the fire-attention layer is in the form of non-woven fabric, the forming method can be dry or wet forming.
  • the consolidation method of the fibers can be thermal bonding, needle punching, or hydroentangling. Considering the application in electric vehicles, it is necessary to fully consider the influence of thickness on the overall energy density of the battery and the functional requirements of thermal management.
  • the lengths of the thermosetting fibers and thermoplastic fibers are preferably 2-38 mm, more preferably 2-10 mm, from the viewpoint of engineering difficulty.
  • the fiber fineness of the single fiber is preferably 0.1 to 7D in view of the dispersibility of the fiber in the raw solution.
  • the lengths of both thermosetting fibers and thermoplastic fibers are preferably 42-80 mm, more preferably 48-76 mm, in view of the carding passability of the fibers.
  • the fineness of each fiber is preferably 0.8 to 10D, and more preferably 1.5 to 6D.
  • the lengths of both thermosetting fibers and thermoplastic fibers are preferably 42-76 mm, more preferably 48-60 mm, from the viewpoint of cardability and formability of fibers .
  • the fineness of each fiber is preferably 0.8 to 10D, and more preferably 1.5 to 6D.
  • the lengths of both thermosetting fibers and thermoplastic fibers are preferably 42-76 mm, more preferably 48-60 mm, from the viewpoint of fiber cardability and formability.
  • the fineness of each fiber is preferably 0.8 to 10D, and more preferably 1.5 to 6D.
  • thermosetting fibers in the fire-resistant layer is preferably 20-80%.
  • the flame-shielding function of the fire-resistant layer in the present invention is achieved by the combination of thermosetting fibers and thermoplastic fibers, wherein the thermosetting fibers are not in flames. It will produce melt shrinkage and is the skeleton fiber in the non-woven fabric. When heated, it can be used for thermoplastic fiber melt droplets to spread between the fibers to form a film, wrap the thermosetting fiber itself, block oxygen, and promote oxygen-free carbonization, thereby improving fire protection. Flame retardant properties of flame retardant non-woven fabrics.
  • thermosetting fibers If the content of thermosetting fibers is too low, the supporting function of the skeleton material will become insufficient, and the thermoplastic fibers will form shrinkage holes after melting, and the prepared non-woven fabric will lose the flame shielding function. On the other hand, if the content of the thermosetting fibers is too high, the thermoplastic fibers cannot be sufficiently spread into a film, and the thermosetting fibers are sufficiently wrapped and sealed, so that the oxygen cannot be blocked, and the decomposition is accelerated. Therefore, the content of the above-mentioned thermosetting fibers is more preferably 30 to 80%, considering that the thermosetting fibers serving as the skeleton can sufficiently support the molten thermoplastic fibers when exposed to flame.
  • thermosetting fibers are preferably pre-oxidized fibers, phenolic fibers, flame-retardant modified viscose fibers or meta-aramid fibers, and from the viewpoint of the thermal decomposition temperature of the fibers and the melt heat shrinkage, the thermosetting fibers are more preferably pre-oxidized fibers or meta-position fibers.
  • Aramid fiber preferably pre-oxidized fibers or meta-position fibers.
  • the thermoplastic fiber B is preferably selected from the group consisting of anisotropic molten polyester, flame-retardant poly(alkylene terephthalate), flame-retardant poly(acrylonitrile-butadiene-styrene), flame-retardant poly(alkylene terephthalate), Sulfones, poly(ether-ether-ketone), poly(ether-ketone-ketone), polyethersulfone, polyarylate, polyphenylsulfone, polyetherimide, polyamideimide, and mixtures thereof Fiber formed from resin. These may be used alone, or two or more of them may be used simultaneously.
  • the polyphenylene sulfide fiber contains sulfur element, which can release sulfur dioxide gas when heated, which has an inhibitory effect on combustion, and can promote carbonization and further improve fire resistance. Therefore, the thermoplastic fibers are preferably polyphenylene sulfide fibers (hereinafter referred to as PPS fibers).
  • the above-mentioned inorganic sheet-like material is preferably mica, glass fiber mat, ceramic or quartz.
  • Mica is formed by aluminosilicates of potassium, aluminum, magnesium, iron or lithium. It is a hexagonal rock-forming mineral with the characteristics of insulation and high temperature resistance. The mixture is bonded together to form a paper-like mica material that is extremely resistant to high temperatures. Paper-like mica material not only has the characteristics of insulation and high temperature resistance, but also improves the shortcomings of poor toughness and brittleness of mica material itself, and can be used as a flexible material.
  • Glass fiber mat is a mat formed by laying and consolidating glass fibers.
  • Ceramics are inorganic non-metallic materials formed by high temperature sintering of one or more of alumina, zirconia, titania and tin oxide. Quartz is a mineral composed of silica, which is an extremely heat-resistant inorganic material with a melting temperature of up to 1750 degrees. In view of the processability and adhesion of the inorganic sheet-like material of the present invention, the inorganic sheet-like material is more preferably mica.
  • the breakdown voltage of the flame-resistant felt of the present invention is preferably 3000-5000V.
  • the dielectric will lose its dielectric properties and become a conductor under the action of a strong enough electric field, which is called dielectric breakdown, and the corresponding voltage is called breakdown voltage.
  • the flame-resistant felt of the present invention plays the role of fire prevention and heat insulation when applied to the upper cover of the battery of the lithium ion battery automobile. When the ion battery is out of control, the electrode will discharge outward. At this time, the upper cover of the battery must have high electrical insulation performance. The higher the breakdown voltage of the flame felt, the more difficult it is for the battery to break down the upper cover to discharge.
  • the breakdown voltage of the flame-resistant felt of the present invention is more preferably 3500-5000V.
  • DTA differential thermal analysis
  • the flame-resistant felt sample is sampled in a square with the size of 1cm ⁇ 1cm, and 10 pieces are taken to weigh their weight N1, and calculate their square gram weight Q1. Heat it with an alcohol blowtorch at 1000 degrees Celsius for 30 minutes, the remaining material is the barrier layer, weigh its mass N2, and calculate its square gram weight Q2, and take the average value.
  • the specific combustion method is as follows: take an A4 size sample, fix it on the metal frame, place it vertically, and use a butane spray gun to face the fixed sample.
  • the model of the spray gun is 920, and the gas tank uses 220G standard butane gas
  • the sample is cooled to room temperature, measure the thickness after combustion, and record it as D2. The number of experiments was 5, and the average value was taken.
  • the thickness ratio of the upper and lower surface fire layers refers to the ratio of the thickness of the thin layer to the thickness of the thick layer, and the unit is %.
  • the test method is as follows: cut a flat sample, take a complete cross-sectional photo of the sample through an EM microscope, measure and mark the thickness of the upper and lower fire layers according to the interface, and the effective number is 0.1 ⁇ m, among which the thinner layer is recorded as H1, and the thicker layer is recorded as H1.
  • the limiting oxygen index refers to the volume percentage of the minimum amount of oxygen required by the polymer to maintain the combustion of the substance in a mixed gas of oxygen and nitrogen, and the unit is %.
  • the test method of fiber limiting oxygen index is as follows: according to the limiting oxygen index instrument specified in GB/T 5454-1997, the obtained fiber is made into non-woven fabric or fabric, and the sample is tested after adjusting the humidity for 8 to 24 hours according to thickness. Take the average value of five tests as the limiting oxygen index % of the fiber.
  • thermosetting fibers in the fireproof layer.
  • test methods for the remaining weight ratio of thermosetting fibers are as follows:
  • thermosetting fibers When the different fibers cannot be determined from the appearance of the non-woven fabric, 10 parts of fibers are randomly selected, each weighing M1, and the TGA test is carried out. The larger one is the flame retardant thermosetting fiber, and the remaining mass is recorded as M2.
  • the formula for calculating the remaining weight ratio of thermosetting fibers is as follows:
  • thermosetting fiber A Grind 10g of non-woven samples into powder, take a certain amount of powder sample for TGA test, record the weight in grams as M3, and the weight of the sample after weighing the test as M4, because the weight of the residue is the amount of the thermosetting fiber.
  • the weight of the inorganic components, so the residual weight ratio L of the thermosetting fiber is used to calculate the content of the thermosetting fiber A, and the calculation formula is as follows:
  • the continuous boost test is used.
  • the voltage at which the sample breaks down under the specified test conditions Use a sample with a thickness of 2 ⁇ 0.2mm and a parallel-plate electrode. The distance between the two metal plates is 25mm, and the thickness is not less than 10mm.
  • the boosting method is a very slow boosting method, and the test voltage is increased at a uniform speed from 0 until breakdown occurs. If the breakdown occurs mostly between 300s and 600s, the test is considered to be successful.
  • the boost rate is selected as 10V/s.
  • the pre-oxidized fibers with a length of 50 mm, a fineness of 2D, and a limiting oxygen index of 45%, and a polyphenylene sulfide fiber with a length of 51 mm, a fineness of 2D, and a limiting oxygen index of 34%, are in a weight ratio of 40%: 60 % Carry out cotton opening, blending, and carding to obtain a fiber web, which is then reinforced by pre-needling and main needling to obtain a flame-retardant non-woven fabric with a thickness of 0.4 mm as a fire-resistant layer.
  • the content of oxidized fibers is 40%; the mica crystals with a melting temperature of 1375 ° C are bonded by an inorganic adhesive and then dried to make a mica sheet with a thickness of 0.1 mm, and the obtained mica sheet is used as a barrier layer;
  • the three-in-one needling method combines two fire-resisting layers and a barrier layer together, the thickness ratio of the upper and lower fire-resisting layers is 100%, and finally a flame-resistant felt with a bulk density of 1540kg/ m3 is obtained.
  • the physical properties of the flame-resistant felt of the present invention are shown in Table 1.
  • the pre-oxidized fibers with a length of 50 mm, a fineness of 2D, and a limiting oxygen index of 45%, and a polyphenylene sulfide fiber with a length of 51 mm, a fineness of 2D, and a limiting oxygen index of 34%, are in a weight ratio of 40%: 60 % Carry out cotton opening, cotton blending and carding to obtain a fiber web, which is then reinforced by pre-needling and main needling to obtain a flame-retardant non-woven fabric with a thickness of 0.4 mm as a fire-resistant layer.
  • the content of oxidized fibers is 38%; the glass fibers with a melting temperature of 1130°C are bonded by inorganic binders and then dried to make a glass fiber mat with a thickness of 0.1 mm, and the obtained glass fiber mat is used as a barrier layer; Then, the two fire-resistant layers and one barrier layer are combined together by the method of three-in-one needle punching.
  • the thickness ratio of the fire-resistant layers on the upper and lower surfaces is 100%, and finally a flame-resistant felt with a bulk density of 1490kg/ m3 is obtained. .
  • the physical properties of the flame-resistant felt of the present invention are shown in Table 1.
  • the pre-oxidized fibers with a length of 50 mm, a fineness of 2D, and a limiting oxygen index of 45%, and a polyphenylene sulfide fiber with a length of 51 mm, a fineness of 2D, and a limiting oxygen index of 34%, are in a weight ratio of 41%: 59 %
  • the content of oxidized fibers is 41%; the mica crystals with a melting temperature of 1375 ° C are bonded by inorganic adhesives and then dried to make mica sheets with a thickness of 0.1 mm, and the obtained mica sheets are used as a barrier layer;
  • the three-in-one needling method combines two fire-resisting layers and a barrier layer, and the thickness ratio of the fire-resisting layers on the upper and lower surfaces is 100%.
  • a flame-resistant felt with a bulk density of 2100kg/m 3 is obtained.
  • the physical properties of the flame-resistant felt of the present invention are shown in Table 1.
  • Pre-oxidized fibers with a length of 50mm, a fineness of 2D, and a limiting oxygen index of 45%, and a flame retardant polyester with a length of 51mm, a fineness of 2D, and a limiting oxygen index of 28% are carried out according to the weight ratio of 40%: 60% Open cotton, blend cotton, and card to obtain a fiber web, which is then reinforced by pre-needling and main needling to obtain a flame-retardant non-woven fabric with a thickness of 0.4 mm as a fire-resistant layer.
  • the pre-oxidized fibers in the fire-resistant layer The content rate of mica is 40%; the mica crystal with a melting temperature of 1375 ° C is bonded by an inorganic binder and then dried to make a mica sheet with a thickness of 0.1 mm, and the obtained mica sheet is used as a barrier layer; A needling method combines two fire-resistant layers and a barrier layer together, and the thickness ratio of the upper and lower surfaces of the fire-resistant layers is 100%, and finally a flame-resistant felt with a bulk density of 1500kg/m 3 is obtained.
  • the physical properties of the flame-resistant felt of the present invention are shown in Table 1.
  • the flame-retardant viscose fiber with a length of 50mm, a fineness of 2D and a limiting oxygen index of 27%, and a polyphenylene sulfide fiber with a length of 51mm, a fineness of 2D and a limiting oxygen index of 34%, are 39% by weight : 61% of cotton is opened, mixed with cotton and carded to obtain a fiber web, which is then reinforced by pre-needling and main needling to obtain a flame-retardant non-woven fabric with a thickness of 0.4mm as a fire-resistant layer.
  • the content rate of the flame retardant viscose fiber is 39%; the mica crystal with a melting temperature of 1375 ° C is bonded by an inorganic adhesive and then dried to make a mica sheet with a thickness of 0.1 mm, and the obtained mica sheet is used as a barrier. Then the two fire-resistant layers and one barrier layer are combined by the three-in-one acupuncture method, and the thickness ratio of the fire - resistant layers on the upper and lower surfaces is 100%. Flame Felt.
  • the physical properties of the flame-resistant felt of the present invention are shown in Table 1.
  • the flame retardant viscose fiber with a length of 51mm, a fineness of 2D, and a limiting oxygen index of 27%, and a flame retardant polyester fiber with a length of 51mm, a fineness of 2D, and a limiting oxygen index of 28%, are 40% by weight: 60% of the cotton is opened, mixed with cotton, and carded to obtain a fiber web, which is then reinforced by pre-needling and main needling to obtain a non-woven fabric with a thickness of 0.4 mm as a fire-resistant layer.
  • the content rate of burning viscose fiber is 40%; the mica crystal with a melting temperature of 1375 ° C is bonded by an inorganic adhesive and then dried to make a mica sheet with a thickness of 0.1 mm, and the obtained mica sheet is used as a barrier layer; Then, the two fire-resistant layers and one barrier layer are combined together by the method of three-in-one needle punching.
  • the thickness ratio of the fire-resistant layers on the upper and lower surfaces is 100%, and finally a flame-resistant felt with a bulk density of 1550kg/ m3 is obtained. .
  • the physical properties of the flame-resistant felt of the present invention are shown in Table 1.
  • the pre-oxidized fibers with a length of 50 mm, a fineness of 2D, and a limiting oxygen index of 45%, and a polyphenylene sulfide fiber with a length of 51 mm, a fineness of 2D, and a limiting oxygen index of 34%, are in a weight ratio of 23%: 77 %
  • the fiber content is 23%; the mica crystals with a melting temperature of 1375 ° C are bonded by an inorganic binder and then dried to make a mica sheet with a thickness of 0.1 mm, and the obtained mica sheet is used as a barrier layer;
  • the combined needling method combines two fire-resistant layers and a barrier layer together, the thickness ratio of the upper and lower fire-resistant layers is 100%, and finally a flame-resistant felt with a bulk density of 1600kg/m 3 is obtained.
  • the physical properties of the flame-resistant felt of the present invention are shown in Table 1.
  • the pre-oxidized fibers with a length of 50 mm, a fineness of 2D, and a limiting oxygen index of 45%, and a polyphenylene sulfide fiber with a length of 51 mm, a fineness of 2D, and a limiting oxygen index of 34%, are in a weight ratio of 38%: 62 %
  • Table 1 The physical properties of the flame-resistant felt of the present invention are shown in Table 1.
  • the pre-oxidized fibers with a length of 50 mm, a fineness of 2D, and a limiting oxygen index of 45%, and a polyphenylene sulfide fiber with a length of 51 mm, a fineness of 2D, and a limiting oxygen index of 34%, are in a weight ratio of 40%: 60 % Carry out cotton opening, cotton blending, and carding to obtain a fiber web, which is then reinforced by pre-needling and main needling to obtain non-woven fabrics with a thickness of 0.55mm and 0.25mm as the fire-resistant layer.
  • the content rate of the pre-oxidized fiber is 40%; the glass fiber with a melting temperature of 1130 ° C is bonded by an inorganic binder and then dried to make a glass fiber mat with a thickness of 0.1 mm, and the obtained glass fiber mat is used as a barrier. Then two fire-resistant layers and a barrier layer are combined together by the method of three-in-one acupuncture, and the thickness ratio of the fire - resistant layers on the upper and lower surfaces is 45%. Flame Felt.
  • the physical properties of the flame-resistant felt of the present invention are shown in Table 1. Among them, the thickness retention rate of the flame-resistant felt is recorded according to the test results from the thin/thick directions, respectively.
  • the pre-oxidized fibers with a length of 50 mm, a fineness of 2D, and a limiting oxygen index of 45%, and a polyphenylene sulfide fiber with a length of 51 mm, a fineness of 2D, and a limiting oxygen index of 34%, are in a weight ratio of 40%: 60 %
  • the content of pre-oxidized fibers in the fire-resistant layer is %.
  • the tin dioxide ceramic material with a melting temperature of 1127 ° C is bonded into a sheet with an inorganic adhesive as a barrier layer; two fire layers and a barrier layer are then bonded by three-in-one acupuncture method. Combined together, the thickness ratio of the upper and lower surfaces of the fire-resistant layers is 100%, and finally a flame-resistant felt with a bulk density of 1518kg/m 3 is obtained.
  • the physical properties of the flame-resistant felt of the present invention are shown in Table 1.
  • the pre-oxidized fibers with a length of 50 mm, a fineness of 2D, and a limiting oxygen index of 45%, and a polyphenylene sulfide fiber with a length of 51 mm, a fineness of 2D, and a limiting oxygen index of 34%, are in a weight ratio of 40%: 60 % to open cotton, blend cotton, and card to obtain a fiber web, which is then reinforced by pre-needling and main needling to obtain a flame-retardant non-woven fabric with a thickness of 0.4mm and 0.5mm, respectively, as a fire-resistant layer.
  • the content of pre-oxidized fibers in the layer is 40%; mica crystals with a melting temperature of 1375 ° C are bonded by inorganic binders and then dried to make mica sheets with a thickness of 0.1 mm, and the obtained mica sheets are used as a barrier. Then, the two fire-resistant layers and one barrier layer are combined together by the method of three-in-one acupuncture, and the thickness ratio of the fire - resistant layers on the upper and lower surfaces is 80%. Flame Felt.
  • the physical properties of the flame-resistant felt of the present invention are shown in Table 1. Among them, the thickness retention rate of the flame-resistant felt is recorded according to the test results from the thin/thick directions, respectively.
  • the pre-oxidized fibers with a length of 50 mm, a fineness of 2D, and a limiting oxygen index of 45%, and a polyphenylene sulfide fiber with a length of 51 mm, a fineness of 2D, and a limiting oxygen index of 34%, are in a weight ratio of 40%: 60 % to open cotton, blend cotton, and card to obtain a fiber web, which is then reinforced by pre-needling and main needling to obtain a flame-retardant non-woven fabric with a thickness of 0.4 mm as a fire-resistant layer; the melting temperature is 1375 °C
  • the mica crystals are bonded by inorganic binders and then dried to make mica sheets with a thickness of 0.1mm, and the obtained mica sheets are used as barrier layers; The layers of barrier layers were bonded together, resulting in a felt with a bulk density of 900 kg/ m3 .
  • the physical properties of the felt are shown in Table 2.
  • the pre-oxidized fibers with a length of 50 mm, a fineness of 2D, and a limiting oxygen index of 45%, and a polyphenylene sulfide fiber with a length of 51 mm, a fineness of 2D, and a limiting oxygen index of 34%, are in a weight ratio of 40%: 60 % Open cotton, blend cotton, and card to obtain a fiber web, which is then reinforced by pre-needling and main needling to obtain a flame-retardant non-woven fabric with a thickness of 0.4 mm as a fire-resistant layer; the melting temperature is 660 ° C
  • the aluminum is rolled into a thin film with a thickness of 0.01mm, which is used as a barrier layer; then the two fireproof layers and a layer of barrier layer are combined together by a three-in-one acupuncture method, and finally the bulk density is 1500kg/ m 3 felt.
  • Table 2 The physical properties of the felt are shown in Table 2.
  • the pre-oxidized fibers with a length of 50 mm, a fineness of 2D, and a limiting oxygen index of 45%, and a polyphenylene sulfide fiber with a length of 51 mm, a fineness of 2D, and a limiting oxygen index of 34%, are in a weight ratio of 40%: 60 % Carry out cotton opening, cotton blending, and carding to obtain a fiber web, which is then reinforced by pre-needling and main needling to obtain a flame-retardant non-woven fabric with a thickness of 0.4 mm as a fire-resistant layer;
  • the mica crystals are bonded by an inorganic binder and then dried to make a mica sheet with a thickness of 0.1 mm, and the obtained mica sheet is used as a barrier layer; then a fire-proof layer and a barrier layer are formed by a two-in-one acupuncture method.
  • the layers are bonded together, resulting in a felt with a bulk density of 1500 kg/ m
  • Example 1 It can be seen from Example 1 and Example 2 that under the same conditions, the melting temperature of the inorganic sheet-like material of the former is within the preferred range.
  • the thickness retention rate after the burning test is higher, and the breakdown voltage of the flame-resistant felt under a certain thickness is also higher.
  • Example 2 It can be seen from Example 1 and Example 3 that under the same conditions, the bulk density of the former is within the preferred range, and compared with the latter, the thickness of the flame-resistant felt made by the former after the butane spray gun burning test The retention rate is higher, and the breakdown voltage of the flame-resistant felt under a certain thickness is also higher.
  • Example 1 and Example 4 It can be seen from Example 1 and Example 4 that under the same conditions, the limiting oxygen index of the thermoplastic fibers in the former fire-resistant layer is in a more preferred range, and compared with the latter, the flame-resistant felt prepared by the former The thickness retention rate is higher after the butane spray gun burning test, and the breakdown voltage of the flame-resistant felt is also higher at a certain thickness.
  • Example 1 and Example 5 It can be seen from Example 1 and Example 5 that under the same conditions, the limiting oxygen index of the thermosetting fibers in the fire-resistant layer of the former is in a more preferable range, and the high temperature resistance is also stronger. Compared with the latter, the former has The obtained flame-resistant felt has a higher thickness retention rate after the butane spray gun burning test, and the breakdown voltage of the flame-resistant felt under a certain thickness is also higher.
  • Example 1 and Example 6 It can be seen from Example 1 and Example 6 that, under the same conditions, the limiting oxygen indices of thermoplastic fibers and thermosetting fibers in the former flame-retardant layer are both within a more preferred range. Compared with the latter, the former flame-retardant layer has a The flame retardant and temperature resistance performance is better, the thickness retention rate of the final composite flame-resistant felt after the butane spray gun burning test is higher, and the breakdown voltage of the flame-resistant felt under a certain thickness is also higher.
  • Example 1 and Example 7 It can be seen from Example 1 and Example 7 that under the same conditions, the content of thermosetting fibers in the former fire-resistant layer is within a more preferable range, and compared with the latter, the temperature resistance of the fire-resistant layer prepared by the former is higher. Even better, the thickness retention rate of the final composite flame-resistant felt after the butane spray gun burning test is higher, and the breakdown voltage of the flame-resistant felt under a certain thickness is also higher.
  • Example 1 and Example 8 It can be seen from Example 1 and Example 8 that under the same conditions, the preparation method of the former fire-resistant layer is a more preferred acupuncture reinforcement method, and compared with the latter, the temperature resistance of the former fire-resistant layer is also better. Well, the thickness retention rate of the final composite flame-resistant felt after the butane gun burn test is higher, and the breakdown voltage of the flame-resistant felt is also higher at a certain thickness.
  • Example 9 the thickness retention rate of the flame-resistant felt was 50% after using a butane spray gun to burn the thinner surface of the fire-facing layer for 5 minutes. After burning the thicker surface of the fire-resistant layer for 5 minutes, the thickness retention rate of the flame-resistant felt is 34%. It can be seen that under the same conditions, the thickness ratio of the former fire-resistant layer is within the preferred range. Compared with the latter, The thickness retention rate of the former flame-resistant felt is higher, and the breakdown voltage of the flame-resistant felt is also higher under a certain thickness.
  • Example 11 It can be seen from Example 1 and Example 11 that in Example 11, when using a butane spray gun to burn the thinner surface of the fire-resistant layer for 5 minutes, the thickness retention rate of the flame-resistant felt was 58%. After burning the thicker surface of the fire-attacking layer for 5 minutes, the thickness retention rate of the flame-resistant felt is 47%. It can be seen that the flame-resistant blanket of the latter belongs to a slightly eccentric structure, and the thickness of the flame-resistant blanket after different fire-attack layers is burned is 47%. The retention rates are all above 40%, and the breakdown voltage is also the same.
  • Example 1 It can be seen from Example 1 and Comparative Example 1 that under the same conditions, the bulk density of the felt in the latter is too low, the flame shielding ability of the obtained felt is poor, and the thickness retention rate of the felt after burning with a butane spray gun is low , The breakdown voltage of the felt is also extremely low, and the protective function is lost.
  • Example 1 It can be seen from Example 1 and Comparative Example 2 that under the same conditions, the melting temperature of the inorganic sheet-like material in the latter is too low, the thickness of the felt cannot be maintained after being burned by a butane spray gun, and the flame-resistant felt cannot be maintained after burning. Holes are produced and the protective function is lost.
  • Example 1 It can be seen from Example 1 and Comparative Example 3 that under the same conditions, the latter only consists of a fire-resistant layer and a barrier layer. Due to the lack of support of the inorganic sheet-like material, the damage after acupuncture is serious, and the butane spray gun is seriously damaged. When burning, it cannot act as a barrier, and the flame-resistant felt produces voids and loses its protective function.

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Abstract

一种耐火焰毡，包括三层复合结构，上下表面迎火层(A)、中间阻隔层(B)，阻隔层(B)是由温度在1000℃以上的无机片状材料构成，耐火焰毡的体积密度为1200～2300kg/m 3。防火遮焰无纺布具有阻燃性好、耐火焰优异、轻量柔软、绝缘性高的特点，可以应用于电池上盖、汽车内饰以及建筑等各种防火保温等场合。

Description

一种耐火焰毡 技术领域
本发明涉及一种耐火焰毡。
背景技术
在传统的电动汽车的动力电池中，包在电池外的隔热防火材料一般都是由多层复合的云母板或气凝胶填充材料形成的，云母板的每一层均是由小块薄片通过硅系粘合剂粘接，而层与层之间的也是通过粘合剂粘结，一般制得厚度在3～5mm的隔热防火材料，该材料虽然阻燃效果优异，但该材料的强度、硬度较差、密度极大、重量也较大、机械性能不好。然而，使用气凝胶的填充材料，虽然是一种柔性材料，能够承受冲击压缩，但因气凝胶是后期填充，其密度极低，因此需要很大的体积才能获得较好的阻燃效果，也会对车内其他部件的设计造成困难。
如中国专利CN202871380U中公开了一种高阻燃工程防火专用带，虽然该材料的耐高温层采用了无机矿物质层，但该无机矿物质为颗粒堆积物，且层与层之间含有大量的胶粘剂，在超过1000度的火焰灼烧时，粘合剂和有机难燃阻燃布会迅速失效，从而导致颗粒状的无机矿物质泄露，从而导致电缆内金属线被火焰直接加热。
如公开专利WO2021/000927A1公开了一种含有隔热层与吸热层的防火材料，该材料的隔热层为附有气凝胶粉末的多孔质材料形成，这种材料因无机组分过高，不能作为柔性材料，成型非常困难。另外，由于气凝胶未为粉末状，且不具备亲水性，因此，在实际使用过程中会发生掉粉以及难于贴合的现象，该材料不能被应用于电池上盖板来阻隔火焰。
又如中国公开专利CN106757775A中公开了一种耐高温空气过滤材料及其制备方法，该过滤材料由耐高温非织造层、耐高温短纤超细玻璃纤维非织造布层和耐高温非织造布层构成，制得的复合毡用于高温空气过滤领域，一旦遇到明火火焰，由于玻璃纤维等的熔融温度低，未达到火焰的温度，就会出现开孔的现象。
因此，有必要开发出一种既有隔热防火效果，又有柔性、轻量化的衬垫状材料。
发明内容
本发明的目的在于提供一种阻隔火焰时间长、电绝缘性优异、轻量化的耐火焰毡。
本发明的技术解决方案如下：本发明的耐火焰毡包括三层复合结构，上下表面迎火层、中间阻隔层，所述阻隔层是由熔融温度在1000℃以上的无机片状材料构成，所述耐火焰毡的体积密度为1200～2300kg/m 3。
使用1200℃的丁烷喷枪灼烧5分钟后，上述耐火焰毡的厚度保持率优选在40％以上。
使用1200℃的丁烷喷枪灼烧5分钟后，上述阻隔层的剩余重量比例优选为70～100％。
上述迎火层优选是由极限氧指数在25％以上的热固性纤维与极限氧指数在25％以上的热塑性纤维构成的织物或无纺布。
上述热固性纤维在迎火层中的含有率优选为20～80％。
上述热固性纤维优选为预氧化纤维、酚醛纤维、阻燃改性粘胶纤维或间位芳纶系纤维。
上述热塑性纤维B优选为选自各向异性熔融聚酯、阻燃性聚(对苯二甲酸亚烷基酯)、阻燃性聚(丙烯腈-丁二烯-苯乙烯)、阻燃性聚砜、聚(醚-醚-酮)、聚(醚-酮-酮)、聚醚砜、聚芳酯、聚苯基砜、聚醚酰亚胺、聚酰胺酰亚胺及它们的混合物中的树脂形成的纤维。
上述无机片状材料优选为云母、玻璃纤维毡、陶瓷或石英。
本发明耐火焰毡的击穿电压优选为3000～5000V。
本发明的有益效果：本发明的耐火焰毡可以直接接触高达1200℃的明火，而且具有优异的电绝缘性能以及阻隔火焰时间长的特点。另外，与同性能无机材料相比，还有轻量化的优点。
附图说明
图1为本发明耐火焰毡的示意图，图中A为迎火层，B为阻隔层，其中a为热固性纤维，b为热塑性纤维。
具体实施方式
本发明的耐火焰毡包括三层复合结构，上下表面迎火层、中间阻隔层，所述阻隔层是由熔融温度在1000℃以上的无机片状材料构成，所述耐火焰毡的体积密度为1200～2300kg/m 3。这里的迎火层是指分布在复合材料的上表面与下表面，直接暴露在空气当中，当发生燃烧或高温的情况时，可以首先接触到火焰或高温的层面。这里的阻隔层是指分布在复合材料的中间部位，当火焰和高温将外侧的迎火层燃烧分解之后，阻隔层因具备超高的耐温性能，因而可以将火焰阻隔拦截，同时还具有一定的隔热性能，从而使未直接接触火焰一侧的迎火层保持一定的形状。上下表面迎火层以及中间阻隔层必须限制各层的位置，如果耐火焰毡只为双层结构的话，即一层迎火层和一层阻隔层，由于阻隔层是由无机片状材料构成，在物理机械复合时，如果没有在两层迎火层夹层保护的情况下，很容易对阻隔层造成损伤，受损的无机材料就会从迎火层上掉落。
构成本发明耐火焰毡的阻隔层是由熔融温度在1000℃以上的无机片状材料构成的，熔融温度是指物质发生熔融的温度，熔融是指温度升高时，分子的热运动动能增大，导致结晶破坏，物质由晶相变为液相的过程。这里的熔融温度是指将固体由固态转变为液态的温度，当材料所处的环境温度高于其熔融温度时，材料内部的分子原子因受热而加剧运动，最终挣脱分子原子之间的键或结合，导致材料开始熔化，由固态转变为液态。材料的熔融温度越高，使用时可以经受的环境温度就越高；材料的熔融温度越低，就越容易发生熔解流动，失去阻隔作用。因此，考虑到本发明耐火焰毡的耐温性能以及性价比，阻隔层中无机片状材料的熔融温度在1000℃以上，优选1200～1800℃。
本发明的阻隔层是采用无机材料构成的，如果采用有机材料制得阻隔层的话，具有较差的耐高温性能。这里的无机材料是指除碳酸盐和碳氧化合物以外的不含碳原子的化合物材料。该无机片状材料是一种厚度范围为0.5～1mm，长宽至少是厚度10倍以上的长方体状材料。本发明无机片状材料的密度均比高分子材料大，例如云母、玻璃纤维或玄武岩纤维，因此，随着无机片状材料厚度的增加，其质量也会有增加，如果无机片状材料过厚，不仅柔性变差，而且还会影响耐火焰毡整体的轻量化。当无机片状材料的厚度过厚时，采用该无机片状材料制得的隔热层就很难与迎火层复合，从而难于进一步制备一体成型材 料；当无机片状材料的厚度过薄时，经过贴合加工的阻隔层会破损，阻隔层就不能起到阻隔火焰的作用。
本发明耐火焰毡的体积密度是与上下表面迎火层以及阻隔层有关，迎火层是由纤维构造体形成，纤维构造体的体积密度一般小于900kg/m 3，阻隔层是由无机片状材料形成，无机片状材料的体积密度一般大于2500KG/m 3。当耐火焰毡的尺寸一定时，其体积密度的大小与阻隔层以及迎火层的比例有关，体积密度也指表观密度，即材料的质量与表观体积之比。阻隔层的密度应大于迎火层的密度，如果耐火焰毡的体积密度大于2300kg/m 3的话，即阻隔层在整个耐火焰毡中的厚度比率大于90％时，说明阻隔层所占的比例过大，即无机片状材料的含量过多，虽然阻隔火焰能力变强，阻隔火焰的时间也会变长，但阻隔层过厚的话，整体的耐火焰毡重量就会过大，不利于电池能量密度的提升，也对实现轻量化造成了实质上的困难；如果耐火焰毡的体积密度小于1200kg/m 3的话，即阻隔层在整个耐火焰毡中的厚度比率小于20％时，说明阻隔层所占的比例过小，即无机片状材料的含量过少，相对的迎火层的厚度也就增大，在被火焰灼烧时整体的阻隔火焰能力就会下降，导致危险的发生。考虑到阻隔火焰的时间以及毡的轻量化，本发明耐火焰毡的体积密度优选1200～1800kg/m 3。
上述阻隔层在整个耐火焰毡中占的比例优选为30～90重量％，如果阻隔层所占的比例过大的话，无机片状材料的含量过多，虽然阻隔火焰能力变强，阻隔火焰的时间也会变长，但阻隔层过厚的话，整体的耐火焰毡重量就会过大，不利于电池能量密度的提升，也对实现轻量化造成了实质上的困难；如果阻隔层所占的比例过小的话，即无机片状材料的含量过少，相对的迎火层的厚度也就增大，在被火焰灼烧时整体的阻隔火焰能力就会下降，导致危险的发生。考虑到阻隔火焰的时间以及毡的轻量化，阻隔层在整个耐火焰毡中占的比例更优选为30～80重量％。
使用1200℃的丁烷喷枪灼烧5分钟，上述耐火焰毡的厚度保持率优选在40％以上，这里的厚度保持率是指当耐火焰毡某一位置在丁烷喷枪灼烧5分钟后，被灼烧部位的厚度占灼烧前该部位厚度的百分比，且厚度保持率是衡量耐火焰毡的防火隔热性能的一个重要指标。本发明耐火焰毡的厚度保持率实际上是靠迎火层和阻隔层的厚度配比达成的，这里不限制各层的厚度，上表面迎火层的厚度与下表面迎火层的厚薄可以相同，也可以不同。当两侧迎火层的厚度相同时，或者当两侧迎火层的厚度不同，即耐火焰毡为稍偏心的结构时，也就是两侧迎火层的厚度比例在50％以上时，使用1200℃的丁烷喷枪灼烧迎火层的任意一面5分钟后，耐火焰毡的厚度保持率可以达到40％以上。当耐火焰毡为极偏心的结构时，即两侧迎火层厚度比例小于50％时，为了使耐火焰毡的厚度保持率可以达到40％以上，应该以较薄的一侧迎火层接触火焰，损失的厚度较少，总体厚度保持率能够保持在40％以上，因此极偏心的场合时，最好以较薄的一层迎火层优先接触火焰。如果以较厚一侧直接接触火焰，那么三层复合材料的厚度损失会很大，耐火焰毡的厚度保持率就会低于40％。考虑到耐火焰毡在实际使用时可能无法限定接触火焰的是迎火层的薄层还是厚层，因此本发明的上下两层迎火层的厚度比例优选为56～100％。两层迎火层的厚度比例是指薄层与厚层的厚度比值，与其所在具***置无关。例如：迎火层厚度分别为0.4mm与0.6mm时，该耐火焰毡的迎火层厚度比例为2/3，即66.7％。
由于本发明的耐火焰毡的应用之一是在锂离子电池汽车的电池内，即防火遮焰材料与电池上的盖板贴合，从而达到隔热防火的效果。当锂离子电池发生 热失控，导致升温失火甚至***时，电池内的温度会在一分钟内升至1000度以上，因此选择使用燃烧温度在1000度以上的丁烷焰，也可以使用温度在1000度以上的其他火焰。如果单纯使用液态电解质的镍钴锰三元锂电池或镍钴铝三元锂电池，虽然在提高正极材料中镍的含量时，可以提高电池的能量密度，但是会影响材料的稳定程度，最终导致电池整体的稳定性和安全性下降。而本发明的耐火焰毡就可以提供良好的阻隔火焰以及高温的效果，将本发明的毡与汽车上的锂电池组合，可以有效阻挡该火焰，防止火焰燃烧到盖板上，火焰不会直接灼烧乘客舱。如果耐火焰毡的厚度保持率过低的话，在1100℃火焰燃烧5分钟后，毡的厚度无法残留或很薄，这就意味着被灼烧部位无纺布的厚度过薄，而材料的隔热性能即热阻就会变差，在材料本身与结构不变的情况下，热阻仅与材料的厚度有关，材料的厚度越厚，热量从材料一端传导到另一端所需要的时间就越长，升温所需要的时间也越长，发生热失控时，耐火焰毡对客舱的保护能力就越高；材料的厚度越薄，热量从一端传导到另一端所需要的时间就越短，升温所需要的时间也越短，发生热失控时，耐焰毡对客舱的保护能力就越低。因此，过薄的厚度会导致毡的隔热效果变差，在高温的情况下，火焰入侵到乘客舱，造成生命财产的损害。考虑到毡的耐火焰、耐高温性能以及相对的隔热性能，使用丁烷喷枪灼烧5分钟后，本发明耐火焰毡的厚度保持率更优选在40～60％，进一步优选50～60％。
使用1200℃的丁烷喷枪灼烧5分钟，上述阻隔层的剩余重量比例优选为70～100％，阻隔层的剩余重量比例是指阻隔层在1200度的温度下加热5分钟后，所剩余的无机片状材料重量占处理前无机片状材料的重量之比。无机片状材料在受高温影响时，会发生某些物理化学的分解，导致阻隔层的厚度以及质量下降。另外，由于某些无机材料的熔点达不到1200℃，比如石棉矿物纤维，在遇到高温时会出现缓慢地熔融流出，阻隔层的质量损失，从而阻隔层的剩余重量比例会相对比较低。因此，无机片状材料的熔融温度优选在1200℃以上。阻隔层中无机片状材料在受热后的剩余重量比例越高，说明阻隔层的形状保持程度就越高，意味着阻隔高温火焰的能力就越强。如果阻隔层的剩余重量比例过小的话，说明经过1200℃高温处理后阻隔层的材料因物理或化学原因产生了质量减少，即被火焰灼烧的位置的材料变薄，引起了热阻的下降。因此，考虑到材料整体的安全性需求，本发明隔层的剩余重量比例更优选为80～100％。
本发明迎火层优选是由极限氧指数在25％以上的热固性纤维与极限氧指数在25％以上的热塑性纤维构成的织物或无纺布。所谓热固性纤维是指受热后不会软化熔融就发生分解或降解的纤维状材料，该材料直径在100μm以下，长径比大于500μm，如天然纤维中的棉纤维、亚麻纤维、苎麻纤维，化学纤维中的粘胶纤维、间位芳纶系纤维、预氧化纤维以及碳纤维。热塑性纤维是指受热后纤维先软化熔融成液态，然后再发生分解的纤维状材料，本发明热固性纤维与热塑性纤维的极限氧指数均在25％以上。极限氧指数是指聚合物在氧和氮混合气体中用于维持物质的燃烧所需要的最小氧气量的容积百分率，是表征材料燃烧性的指标。极限氧指数越高，就越难于燃烧；极限氧指数越低，就越容易发生燃烧并且产生火焰，从而就无法起到防火遮焰的效果。因此，热固性纤维的极限氧指数优选为25％以上，更优选为30％以上。热塑性纤维的极限氧指数优选为25％以上，更优选为30％以上。
上述迎火层优选为织物或无纺布。当迎火层为织物形态时，所用的热固性纤维与热塑性纤维可以是长丝形态，也可以纱线形态，当形态为纱线时，考虑 到纺纱工程以及与其他纤维混纺难易度，纤维长度优选30～65mm，更优选为38～51mm，纤维直径优选1～6dtex。当迎火层为无纺布形态时，成网方式可以是干式，也可以是湿式成网。纤维的固结方式，可以是热粘合方式，也可以是针刺法固结，还可以是水刺法固结。考虑到应用于电动车中，需要充分考虑厚度对电池总体能量密度的影响以及热管理的功能需要，无纺布的成网方式优选干式成网，固结方法优选水刺法固结。
当采用湿法抄纸成网的方式制备本发明的迎火层时，从工程难易度方面考虑，热固性纤维以及热塑性纤维的长度优选为2～38mm，更优选为2～10mm。从纤维在原液中的分散性好坏方面来考虑，单纤维的纤维纤度优选为0.1～7D。
当采用干法梳理成网的方式制备本发明的迎火层时，从纤维的梳理通过性来考虑，热固性纤维以及热塑性纤维的长度均优选为42～80mm，更优选为48～76mm。各种纤维的纤度均优选为0.8～10D，更优选为1.5～6D。
当采用干法针刺固结的方式制备本发明的迎火层时，从纤维的梳理性以及成型性方面考虑，热固性纤维以及热塑性纤维的长度均优选为42～76mm，更优选为48～60mm。各纤维的纤度均优选为0.8～10D，更优选为1.5～6D。
当采用水刺法固结的方式制备本发明的迎火层时，从纤维的梳理性以及成型性方面考虑，热固性纤维以及热塑性纤维的长度均优选为42～76mm，更优选为48～60mm。各纤维的纤度均优选为0.8～10D，更优选为1.5～6D。
上述热固性纤维在迎火层中的含有率优选为20～80％，本发明中迎火层的遮焰功能是由热固性纤维与热塑性纤维组合后所达到的效果，其中热固性纤维在火焰燃烧时不会产生熔融收缩，是无纺布中的骨架纤维，在受热时可以供热塑性纤维熔融液滴在纤维间铺展成膜，并将热固性纤维本身包裹，阻隔氧气，促进无氧碳化，从而提高防火遮焰无纺布的阻燃性能。如果热固性纤维的含量过低的话，则作为骨架材料的支撑作用就变得不充分，热塑性纤维熔融后形成熔缩孔洞，制得的无纺布就会失去遮焰功能。另一方面，如果热固性纤维的含量过高的话，则热塑性纤维无法充分铺展成膜状，将热固性纤维充分包裹密封，这样就无法遮挡氧气，分解变快。因此，考虑到接触火焰时作为骨架的热固性纤维能充分支撑熔融的热塑性纤维，上述热固性纤维的含量更优选为30～80％。
上述热固性纤维优选为预氧化纤维、酚醛纤维、阻燃改性粘胶纤维或间位芳纶系纤维，从纤维的受热分解温度以及熔融热收缩方面考虑，热固性纤维更优选预氧化纤维或间位芳纶纤维。
上述热塑性纤维B优选为选自各向异性熔融聚酯、阻燃性聚(对苯二甲酸亚烷基酯)、阻燃性聚(丙烯腈-丁二烯-苯乙烯)、阻燃性聚砜、聚(醚-醚-酮)、聚(醚-酮-酮)、聚醚砜、聚芳酯、聚苯基砜、聚醚酰亚胺、聚酰胺酰亚胺及它们的混合物中的树脂形成的纤维。它们可以单独使用，也可以同时使用两种以上。其中，聚苯硫醚纤维中含有硫元素，在受热时能释放出二氧化硫气体，对燃烧有抑制作用，并且可以促进碳化，进一步提高防火性能。因此，热塑性纤维优选聚苯硫醚纤维(以下称为PPS纤维)。
上述无机片状材料优选为云母、玻璃纤维毡、陶瓷或石英。云母是由钾、铝、镁、铁或锂的铝硅酸盐形成，它是一种呈六方形的造岩矿物，具有绝缘、耐高温的特性，将薄、面积偏小的云母片采用粘合剂粘结到一起，形成一种极耐高温的纸状云母材料。纸状云母材料不仅具有绝缘、耐高温的特性，而且还改善了云母材料本身韧性差、易碎的缺点，可作为一种柔性材料。玻璃纤维毡 是采用玻璃纤维通过铺网、固结的方式形成的毡。陶瓷是由氧化铝、氧化锆、氧化钛、氧化锡中的一种或几种通过高温烧结形成的无机非金属材料。石英是由二氧化硅组成的矿物，它是一种熔融温度高达1750度的极耐热无机材料。考虑到本发明无机片状材料的加工性以及贴合性，无机片状材料更优选为云母。
本发明耐火焰毡的击穿电压优选为3000～5000V。电介质在足够强的电场作用下将失去其介电性能成为导体，称为电介质击穿，所对应的电压称为击穿电压。由于本发明的耐火焰毡在应用于锂离子电池汽车的电池上盖时，起到防火隔热的作用。离子电池在发生失控时，电极就会向外放电，此时电池上盖板就要具备很高的电绝缘性能，火焰毡的击穿电压越高，电池击穿上盖板产生放电就越难，车舱内就越安全；火焰毡的击穿电压越低，电池击穿上盖板产生放电就越简单，车舱内就越危险。考虑到电压击穿安全问题以及轻量化、成本等问题，本发明耐火焰毡的击穿电压更优选为3500～5000V。
通过以下实施例对本发明作进一步说明，但本发明的保护范围不局限于实施例，实施例中各物性参数由下面方法测定。
【熔融温度】
使用差热分析DTA测得熔融温度在700℃以上的物质的熔点，加热范围为室温至2000℃，升温速度不小于50℃/min。试样质量为5～10mg，在氮气的作用下，吹扫速度为100ml/min，升温速度为15℃/min，起始温度为50℃，终止温度为1600℃。通过仪器配套的分析软件获得质量分数变化量与温度曲线，从曲线上可以得出该物质的熔融温度T。
【体积密度】
根据JIS L 1096-1999，使用电子天平称取10cm×10cm的试样的质量，所得数据乘100，得到换算后的每平方米样品的重量。测量5次，取平均值为最终测试结果M；根据JIS L 1096-1999 8.5，采用手持式厚度仪测量样品的厚度为δ。体积密度计算公式如下：体积密度ρ(kg/m 2)＝M/δ。
【阻隔层所占比例】
将耐火焰毡样品按1cm×1cm大小的正方形取样，取10枚称量其重量N1，并计算其平方米克重Q1。使用1000摄氏度的酒精喷灯对其加热30min，剩余的物质即是阻隔层，称量其质量N2，并计算其平方米克重Q2，均取平均值。阻隔层占耐火焰毡比例的计算公式如下：阻隔层占耐火焰毡的比例为P＝Q1/Q2×100％。
【厚度保持率】
根据JIS L 1096-1999 8.5，采用手持式厚度仪，分别测试5次燃烧前的样品的厚度，记为D1。然后进行燃烧试验，具体燃烧方法为：取A4大小的样品，固定在金属框架上，垂直放置，使用丁烷喷枪正对固定好的样品，其中喷枪型号为920，气罐使用220G标准丁烷气罐，调节喷枪口与样品间的距离为8cm后，打开气体开关，点燃丁烷焰，开始计时，5min后关闭燃气开关，待样品降温至室温后，测量燃烧后的厚度，记为D2。试验次数为5次，取平均值。厚度保持率的计算公式如下：厚度保持率K＝(D1/D2)×100％。
【阻隔层剩余重量比例】
将阻隔层样品按1cm×1cm大小的正方形取样，取5枚。称取燃烧前样品的质量为M1，然后进行燃烧处理。使用钢制固定架将样品固定，同样使用丁烷喷枪进行试验，调整喷枪枪头距离样品8cm，开启气阀到3/5的程度点火，使样品完全进入火焰之中。2分钟之后熄灭火焰，待样品降温至室温，取下样品进 行称量，重量记为M2。M1与M2均取五枚样品的平均数，则阻隔层剩余重量比例的计算公式如下：阻隔层的剩余重量比例L＝M2/M1×100％。
【上下表面迎火层的厚度比例】
上下表面迎火层的厚度比例是指薄层厚度比厚层厚度的比值，单位是％。其测试方法如下：切取平整的样品，通过EM显微镜拍摄完整的样品截面照片，将上下两迎火层按分界面测量标注厚度，其有效数字取0.1微米，其中较薄层记为H1，较厚层记为H2，则上下表面迎火层的厚度比例的计算公式如下：Kh＝(H1/H2)×100％，其中，H1、H2均为取五枚样品截面计算的平均值。
【极限氧指数】
极限氧指数是指聚合物在氧和氮混合气体中用于维持物质的燃烧所需要的最小氧气量的容积百分率，单位是％。纤维极限氧指数的测试方法如下：根据GB/T 5454-1997中规定的极限氧指数仪，将取得的纤维制成无纺布或织物，将试样按厚薄调湿8～24h后进行测试，取五次测试的平均值为该纤维的极限氧指数％。
【热固性纤维的含有率】
首先需要确定迎火层中热固性纤维的剩余重量比例，热固性纤维的剩余重量比例的测试方法有如下两种情况：
1、从迎火层无纺布的外观可以直接确定出两种纤维时，分别取两种纤维各5份，每份重量为M1(毫克级别)，分别进行TGA测试，条件为：25度加热至800度，升温速度20度/分钟，剩余质量较大的为阻燃热固性纤维，剩余质量为M2；
2、当从无纺布的外观无法确定纤维不同时，随机取10份纤维，每份重量为M1，进行TGA测试，条件为：25度加热至800度，升温速度20度/分钟，剩余质量较大的为阻燃热固性纤维，剩余质量记为M2。热固性纤维的剩余重量比例的计算公式如下：
热固性纤维的剩余重量比例L＝M2/M1×100％。
将10g无纺布样品研磨成粉末状，取一定量的粉末样品进行TGA测试，记重量克数为M3，称量试验后样品的重量记为M4，因为此剩余物的重量即是热固性纤维中无机组分的重量，所以利用热固性纤维的剩余重量比例L，计算热固性纤维A的含有率，其计算公式如下：
热固性纤维A的含有率：C＝(M3×M4/L)×100％。
【击穿电压】
按照GB T1408.1-2016标准中的规定，并采用连续升压试验。在规定的试验条件下，试样发生击穿时的电压。使用厚度为2±0.2mm的样品，以及平行板电极，两金属板相距25mm，厚度不小于10mm。升压方式为非常慢速升压方式，将试验电压由0开始以均匀速度上升直至击穿发生。如果击穿大多数发生在300s～600s之间，则认为试验时成功的。选用升压速率为10V/s。
实施例1
将长度为50mm、纤度为2D、极限氧指数为45％的预氧化纤维，以及长度为51mm、纤度为2D、极限氧指数为34％的聚苯硫醚纤维，按照重量比例为40％：60％进行开棉、混棉、梳理，制得纤维网，然后经过预针刺、主针刺进行加固，制得厚度为0.4mm阻燃无纺布作为迎火层，该迎火层中的预氧化纤维的含有率为40％；将熔融温度为1375℃的云母晶体通过无机粘合剂粘合后干燥，制成厚度为0.1mm的云母片，将制得的云母片作为阻隔层；再通过三合一针刺的方法 将两片迎火层和一层阻隔层结合到一起，上下表面迎火层的厚度比例为100％，最后制得体积密度为1540kg/m 3的耐火焰毡。本发明耐火焰毡的各物性参见表1。
实施例2
将长度为50mm、纤度为2D、极限氧指数为45％的预氧化纤维，以及长度为51mm、纤度为2D、极限氧指数为34％的聚苯硫醚纤维，按照重量比例为40％：60％进行开棉、混棉、梳理，制得纤维网，然后经过预针刺、主针刺进行加固，制得厚度为0.4mm阻燃无纺布作为迎火层，该迎火层中的预氧化纤维的含有率为38％；将熔融温度为1130℃的玻璃纤维通过无机粘合剂粘合后干燥，制成厚度为0.1mm的玻璃纤维毡，将制得的玻璃纤维毡作为阻隔层；再通过三合一针刺的方法将两片迎火层和一层阻隔层结合到一起，上下表面迎火层的厚度比例为100％，最后制得体积密度为1490kg/m 3的耐火焰毡。本发明耐火焰毡的各物性参见表1。
实施例3
将长度为50mm、纤度为2D、极限氧指数为45％的预氧化纤维，以及长度为51mm、纤度为2D、极限氧指数为34％的聚苯硫醚纤维，按照重量比例为41％：59％进行开棉、混棉、梳理，制得纤维网，然后经过预针刺、主针刺进行加固，制得厚度为0.4mm阻燃无纺布作为迎火层，该迎火层中的预氧化纤维的含有率为41％；将熔融温度为1375℃的云母晶体通过无机粘合剂粘合后干燥，制成厚度为0.1mm的云母片，将制得的云母片作为阻隔层；再通过三合一针刺的方法将两片迎火层和一层阻隔层结合到一起，上下表面迎火层的厚度比例为100％，最后制得体积密度为2100kg/m 3的耐火焰毡。本发明耐火焰毡的各物性参见表1。
实施例4
将长度为50mm、纤度为2D、极限氧指数为45％的预氧化纤维，以及长度为51mm、纤度为2D、极限氧指数为28％的阻燃涤纶，按照重量比例为40％：60％进行开棉、混棉、梳理，制得纤维网，然后经过预针刺、主针刺进行加固，制得厚度为0.4mm阻燃无纺布作为迎火层，该迎火层中的预氧化纤维的含有率为40％；将熔融温度为1375℃的云母晶体通过无机粘合剂粘合后干燥，制成厚度为0.1mm的云母片，将制得的云母片作为阻隔层；再通过三合一针刺的方法将两片迎火层和一层阻隔层结合到一起，上下表面迎火层的厚度比例为100％，最后制得体积密度为1500kg/m 3的耐火焰毡。本发明耐火焰毡的各物性参见表1。
实施例5
将长度为50mm、纤度为2D、极限氧指数为27％的阻燃粘胶纤维，以及长度为51mm、纤度为2D、极限氧指数为34％的聚苯硫醚纤维，按照重量比例为39％：61％进行开棉、混棉、梳理，制得纤维网，然后经过预针刺、主针刺进行加固，制得厚度为0.4mm阻燃无纺布作为迎火层，该迎火层中的阻燃粘胶纤维的含有率为39％；将熔融温度为1375℃的云母晶体通过无机粘合剂粘合后干燥，制成厚度为0.1mm的云母片，将制得的云母片作为阻隔层；再通过三合一针刺的方法将两片迎火层和一层阻隔层结合到一起，上下表面迎火层的厚度比例为100％，最后制得体积密度为1530kg/m 3的耐火焰毡。本发明耐火焰毡的各物性参见表1。
实施例6
将长度为51mm、纤度为2D、极限氧指数为27％的阻燃粘胶纤维，以及长度为51mm、纤度为2D、极限氧指数为28％的阻燃涤纶纤维，按照重量比例为40％：60％进行开棉、混棉、梳理，制得纤维网，然后经过预针刺、主针刺进行加固，制得厚度为0.4mm的无纺布作为迎火层，该迎火层中的阻燃粘胶纤维的含有率为40％；将熔融温度为1375℃的云母晶体通过无机粘合剂粘合后干燥，制成厚度为0.1mm的云母片，将制得的云母片作为阻隔层；再通过三合一针刺的方法将两片迎火层和一层阻隔层结合到一起，上下表面迎火层的厚度比例为100％，最后制得体积密度为1550kg/m 3的耐火焰毡。本发明耐火焰毡的各物性参见表1。
实施例7
将长度为50mm、纤度为2D、极限氧指数为45％的预氧化纤维，以及长度为51mm、纤度为2D、极限氧指数为34％的聚苯硫醚纤维，按照重量比例为23％：77％进行开棉、混棉、梳理，制得纤维网，然后经过预针刺、主针刺进行加固，制得厚度为0.4mm的无纺布作为迎火层，该迎火层中的预氧化纤维的含有率为23％；将熔融温度为1375℃的云母晶体通过无机粘合剂粘合后干燥，制成厚度为0.1mm的云母片，将制得的云母片作为阻隔层；再通过三合一针刺的方法将两片迎火层和一层阻隔层结合到一起，上下表面迎火层的厚度比例为100％，最后制得体积密度为1600kg/m 3的耐火焰毡。本发明耐火焰毡的各物性参见表1。
实施例8
将长度为50mm、纤度为2D、极限氧指数为45％的预氧化纤维，以及长度为51mm、纤度为2D、极限氧指数为34％的聚苯硫醚纤维，按照重量比例为38％：62％进行开棉、混棉、梳理，制得纤维网，然后经过预针刺、初步加固，再用水刺法进一步加固，制得厚度为0.4mm的无纺布作为迎火层，该迎火层中的预氧化纤维的含有率为38％；将熔融温度为1375℃的云母晶体通过无机粘合剂粘合后干燥，制成厚度为0.1mm的云母片，将制得的云母片作为阻隔层；再通过三合一针刺的方法将两片迎火层和一层阻隔层结合到一起，上下表面迎火层的厚度比例为100％，最后制得体积密度为1520kg/m 3的耐火焰毡。本发明耐火焰毡的各物性参见表1。
实施例9
将长度为50mm、纤度为2D、极限氧指数为45％的预氧化纤维，以及长度为51mm、纤度为2D、极限氧指数为34％的聚苯硫醚纤维，按照重量比例为40％：60％进行开棉、混棉、梳理，制得纤维网，然后经过预针刺、主针刺进行加固，制得厚度为0.55mm和0.25mm的无纺布作为迎火层，该迎火层中的预氧化纤维的含有率为40％；将熔融温度为1130℃的玻璃纤维通过无机粘合剂粘合后干燥，制成厚度为0.1mm的玻璃纤维毡，将制得的玻璃纤维毡作为阻隔层；再通过三合一针刺的方法将两片迎火层和一层阻隔层结合到一起，上下表面迎火层的厚度比例为45％，最后制得体积密度为1518kg/m 3的耐火焰毡。本发明耐火焰毡的各物性参见表1。其中，耐火焰毡的厚度保持率按照分别从薄/厚方向的试验结果记录。
实施例10
将长度为50mm、纤度为2D、极限氧指数为45％的预氧化纤维，以及长度为51mm、纤度为2D、极限氧指数为34％的聚苯硫醚纤维，按照重量比例为40％：60％进行开棉、混棉、梳理，制得纤维网，然后经过预针刺、主针刺加固后得阻燃无纺布作为迎火层，该迎火层中的预氧化纤维的含有率为40％；将熔融温度 的1127℃的二氧化锡陶瓷材，用无机粘合剂粘合成片状作为阻隔层；再通过三合一针刺的方法将两片迎火层和一层阻隔层结合到一起，上下表面迎火层的厚度比例为100％，最后制得体积密度为1518kg/m 3的耐火焰毡。本发明耐火焰毡的各物性参见表1。
实施例11
将长度为50mm、纤度为2D、极限氧指数为45％的预氧化纤维，以及长度为51mm、纤度为2D、极限氧指数为34％的聚苯硫醚纤维，按照重量比例为40％：60％进行开棉、混棉、梳理，制得纤维网，然后经过预针刺、主针刺进行加固，制得阻燃无纺布厚度分别为0.4mm和0.5mm作为迎火层，该迎火层中的预氧化纤维的含有率为40％；将熔融温度为1375℃的云母晶体通过无机粘合剂粘合后干燥，制成厚度为0.1mm的云母片，将制得的云母片作为阻隔层；再通过三合一针刺的方法将两片迎火层和一层阻隔层结合到一起，上下表面迎火层的厚度比例为80％，最后制得体积密度为1540kg/m 3的耐火焰毡。本发明耐火焰毡的各物性参见表1。其中，耐火焰毡的厚度保持率按照分别从薄/厚方向的试验结果记录。
比较例1
将长度为50mm、纤度为2D、极限氧指数为45％的预氧化纤维，以及长度为51mm，纤度为2D，极限氧指数为34％的聚苯硫醚纤维，按照重量比例为40％：60％进行开棉、混棉、梳理，制得纤维网，然后经过预针刺、主针刺进行加固，制得厚度为0.4mm的阻燃无纺布作为迎火层；将熔融温度为1375℃的云母晶体通过无机粘合剂粘合后干燥，制成厚度为0.1mm的云母片，将制得的云母片作为阻隔层；再通过三合一针刺的方法将两片迎火层和一层阻隔层结合到一起，最后制得体积密度为900kg/m 3的毡。该毡的各物性参见表2。
比较例2
将长度为50mm、纤度为2D、极限氧指数为45％的预氧化纤维，以及长度为51mm，纤度为2D，极限氧指数为34％的聚苯硫醚纤维，按照重量比例为40％：60％进行开棉、混棉、梳理，制得纤维网，然后经过预针刺、主针刺进行加固，制得厚度为0.4mm的阻燃无纺布作为迎火层；将熔融温度为660℃的铝延压成薄膜，厚度为0.01mm，以此作为阻隔层；再通过三合一针刺的方法将两片迎火层和一层阻隔层结合到一起，最后制得体积密度为1500kg/m 3的毡。该毡的各物性参见表2。
比较例3
将长度为50mm、纤度为2D、极限氧指数为45％的预氧化纤维，以及长度为51mm，纤度为2D，极限氧指数为34％的聚苯硫醚纤维，按照重量比例为40％：60％进行开棉、混棉、梳理，制得纤维网，然后经过预针刺、主针刺进行加固，制得厚度为0.4mm阻燃无纺布作为迎火层；将熔融温度为1375℃的云母晶体通过无机粘合剂粘合后干燥，制成厚度为0.1mm的云母片，将制得的云母片作为阻隔层；再通过二合一针刺的方法将一片迎火层和一层阻隔层结合到一起，最后制得体积密度为1500kg/m 3的毡。该毡的各物性参见表2。
表1
Figure PCTCN2022082631-appb-000001
表2
Figure PCTCN2022082631-appb-000002
根据上述表：
(1)由实施例1与实施例2可知，同等条件下，前者的无机片状材料的熔融温度在优选范围内，与后者相比，前者所制得的耐火焰毡在丁烷喷枪灼烧试验后的厚度保持率更高，一定厚度下耐火焰毡的击穿电压也更高。
(2)由实施例1与实施例3可知，同等条件下，前者的体积密度在优选范围内，与后者相比，前者所制得的耐火焰毡在丁烷喷枪灼烧试验后的厚度保持率更高，一定厚度下耐火焰毡的击穿电压也更高。
(3)由实施例1与实施例4可知，同等条件下，前者的迎火层中的热塑性纤维的极限氧指数在更优选范围内，与后者相比，前者所制得的耐火焰毡在丁烷喷枪灼烧试验后的厚度保持率更高，一定厚度下耐火焰毡的击穿电压也更高。
(4)由实施例1与实施例5可知，同等条件下，前者的迎火层中的热固性纤维的极限氧指数在更优选范围内，耐高温性能也更强，与后者相比，前者所制得的耐火焰毡在丁烷喷枪灼烧试验后的厚度保持率更高，一定厚度下耐火焰毡的击穿电压也更高。
(5)由实施例1与实施例6可知，同等条件下，前者的迎火层中热塑性纤维与热固性纤维的极限氧指数均在更优选范围内，与后者相比，前者迎火层的阻燃耐温性能更好，最终复合得到的耐火焰毡在丁烷喷枪灼烧试验后的厚度保持率更高，一定厚度下耐火焰毡的击穿电压也更高。
(6)由实施例1与实施例7可知，同等条件下，前者的迎火层中的热固性纤维的含量在更优选范围内，与后者相比，前者制备的迎火层的耐温性能也就更好，最终复合的耐火焰毡在丁烷喷枪灼烧试验后的厚度保持率更高，一定厚度下耐火焰毡的击穿电压也更高。
(7)由实施例1与实施例8可知，同等条件下，前者的迎火层制备方式为更优选的针刺加固方式，与后者相比，前者迎火层的耐温性能也就更好，最终复合的耐火焰毡在丁烷喷枪灼烧试验后的厚度保持率更高，且在一定厚度下耐火焰毡的击穿电压也更高。
(8)由实施例2与实施例9可知，实施例9中当使用丁烷喷枪灼烧迎火层的较薄面5分钟后，耐火焰毡的厚度保持率为50％，当使用丁烷喷枪灼烧迎火层的较厚面5分钟后，耐火焰毡的厚度保持率为34％，由此可知，同等条件下，前者的迎火层厚度比例在优选范围内，与后者相比，前者耐火焰毡的厚度保持率更高，且在一定厚度下耐火焰毡的击穿电压也更高。
(9)由实施例2与实施例10可知，同等条件下，前者在1200℃加热后，阻隔层的剩余重量比例在优选范围内，与后者相比，前者的耐火焰毡在丁烷喷枪灼烧试验后的厚度保持率更高，且在一定厚度下耐火焰毡的击穿电压也更高。
(10)由实施例1与实施例11可知，实施例11中当使用丁烷喷枪灼烧迎火层的较薄面5分钟后，耐火焰毡的厚度保持率为58％，当使用丁烷喷枪灼烧迎火层的较厚面5分钟后，耐火焰毡的厚度保持率为47％，由此可知，后者的耐火焰毡属于稍偏心结构，在不同迎火层被灼烧后的厚度保持率均在40％以上，且击穿电压也相同。
(11)由实施例1与比较例1可知，同等条件下，后者中毡的体积密度过低，所制得毡的遮焰能力差，经丁烷喷枪灼烧后毡的厚度保持率低，毡的击穿电压也极低，丧失防护功能。
(12)由实施例1与比较例2可知，同等条件下，后者中无机片状材料的熔融温度过低，经丁烷喷枪灼烧后毡的厚度无法保持，耐火焰毡在灼烧后产生孔洞，丧失防护功能。
(13)由实施例1与比较例3可知，同等条件下，后者只有一层迎火层与一层阻隔层构成，由于无机片状材料缺乏支撑，针刺复合后损伤严重，丁烷喷枪灼烧时无法起到阻隔作用，耐火焰毡产生空洞，丧失防护功能。

Claims (9)

  1. 一种耐火焰毡，其特征在于，所述耐火焰毡包括三层复合结构，上下表面迎火层、中间阻隔层，所述阻隔层是由熔融温度在1000℃以上的无机片状材料构成，所述耐火焰毡的体积密度为1200～2300kg/m 3。
  2. 根据权利要求1所述的耐火焰毡，其特征在于：使用1200℃的丁烷喷枪灼烧5分钟后，所述耐火焰毡的厚度保持率在40％以上。
  3. 根据权利要求1所述的耐火焰毡，其特征在于：使用1200℃的丁烷喷枪灼烧5分钟后，所述阻隔层的剩余重量比例为70～100％。
  4. 根据权利要求1所述的耐火焰毡，其特征在于：所述迎火层是由极限氧指数在25％以上的热固性纤维与极限氧指数在25％以上的热塑性纤维构成的织物或无纺布。
  5. 根据权利要求4所述的耐火焰毡，其特征在于：所述热固性纤维在迎火层中的含有率为20～80％。
  6. 根据权利要求4所述的耐火焰毡，其特征在于：所述热固性纤维为预氧化纤维、酚醛纤维、阻燃改性粘胶纤维或间位芳纶系纤维。
  7. 根据权利要求4所述的耐火焰毡，其特征在于：所述热塑性纤维B为选自各向异性熔融聚酯、阻燃性聚(对苯二甲酸亚烷基酯)、阻燃性聚(丙烯腈-丁二烯-苯乙烯)、阻燃性聚砜、聚(醚-醚-酮)、聚(醚-酮-酮)、聚醚砜、聚芳酯、聚苯基砜、聚醚酰亚胺、聚酰胺酰亚胺及它们的混合物中的树脂形成的纤维。
  8. 根据权利要求1所述的耐火焰毡，其特征在于：所述无机片状材料为云母、玻璃纤维毡、陶瓷或石英。
  9. 根据权利要求1所述的耐火焰毡，其特征在于:所述耐火焰毡的击穿电压为3000～5000V。
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