KR20090002498A - Up flame-retardant of vehicle for floor carpet and the making method - Google Patents

Abstract

A car floor carpet and the manufacturing method thereof improving the fire retardant characteristic is provided to adhere a flame retardant is not used and non-woven to the latex layer to the exterior material. As a car floor carpet improving the fire retardant characteristic include a napping layer(11) and the latex layer(12) supporting the fiber napping layer, a nonwoven layer(15) adhered to the surface of the latex layer, and a bonding layer(14) sticking the nonwoven layer to the latex layer are comprised. The fiber napping layer is 600~800g/m^2 polyester fiber napping layer, the latex layer is 100~150g/m^2 latex layer, and a non-woven layer is 20~60g/m^2.

Description

Car floor carpet with improved flame retardancy and its manufacturing method {UP FLAME-RETARDANT OF VEHICLE FOR FLOOR CARPET AND THE MAKING METHOD}

1 is a layer configuration diagram of a floor carpet for a conventional vehicle

Figure 2 is a layer diagram of the floor carpet for this invention vehicle

Figure 3 is a manufacturing apparatus diagram of the floor carpet for this invention vehicle

* Explanation of the main signs of the drawings

Reference numeral 10 denotes a conventional car floor carpet, 11 fiber layer, 12 latex layer, 13 coating layer, 14 adhesive layer, and 15 nonwoven fabric layer.

The present invention relates to a floor carpet for automobiles having improved flame retardancy and a method of manufacturing the same.

Carpeting on the interior floor of the car. Car floor carpets enhance the interior space of the car, have sound absorbing and dust-absorbing functions, temperature buffering, and calm passengers' minds.

The specification of the car floor carpet should be (I) suitable for the road driving environment of the car, well-formed for various bends of the floor of the car, good washability, no water or moisture, and closed In the car space, there should be no cold and cold in winter, and in summer, it should not be deformed by hot heat. In addition to these characteristics, it has recently been required to impart flame retardancy (II) to an enhanced standard in order to cope with the danger of automobile fire.

Materials used for automotive floor carpets include woven carpets and nonwoven carpets. The properties of the woven and nonwoven carpets are cited in Table 1.

Table 1. Comparison table of floor carpet properties

 division Woven carpet B.C.F (BULKED CONTINOUS FILAMENT) Needle Punched Carpet NEEDLE PUNCHING CARPET  Recipe and Properties  Fabrics woven with warp and weft in spinning, weaving or knitting processes  Fabrics or sheets in which fiber aggregates are freely bonded by chemically or mechanically treating or heat-treating fiber aggregates   Advantages  Grace is good. (13oz or more) Excellent leveling. Easy to dye Elastic recovery is good.  The price is cheaper than BCF. The strength of the fabric is large, the bending formability is good. It can be cut in any direction. The tip does not loosen like the fabric. Free to choose the thickness. There is no DEEP DRAW’G goal. Thermoforming is good.   Disadvantages  DEEP DRAW'G goal appears on the exterior. Low intensity Short fiber brushing is easy to fall out. Trimming breaks the fabric. The thread is easy to fall out. The price is high.  Low cushion Low wear resistance (PLAIN TYPE)

As shown in the above characteristics, the automobile carpet uses a lot of nonwoven carpets with good trimming processability and thermoformability and low cost. Of course, expensive woven carpets or handmade carpets can be installed in the car interior, but considering the market competitiveness and mass productivity of the car, the nonwoven carpets have good characteristics as car carpets.

The structure and characteristics of the needle punched carpet are summarized in Table 2.

Table 2. Characteristics of Needle Punched Carpet

Needle punching carpet  Remarks division i PLAIN ii HI-VELOUR iii VELOUR   Raising mode

 The raising of woven carpets (BCF CARPET) uses CUT-FILE.  Layer structure  1.PLAIN 2.Latex layer 3.PE coating layer  1.HI VELOUR 2.LATEX LAYER 3.PE COATING LAYER  1.Fiber layer (VELOUR) 2.Latex layer 3.PE coating layer

The main materials of the carpet are summarized in Table 3.

Table 3. Main Materials of Carpet

No. Classification Main material Remarks  One  FIBER  Polyester  2  Latex  Acrylic Binder  3  PE coating  Polyethylene Polyethylene  4  AP coating  TPO (Thermo Plastic Olefin), Adhesive Polymer etc.  5  CUT-FILE  nylon  Weave carpet

The carpet of Tables 1 to 3 satisfies the above specification (I) that the automobile floor carpet should have. However, the carpet does not meet the flame retardancy of specification (II), which is an reinforced specification.

 Existing automotive flame retardant carpet is composed of 600 ~ 800g / ㎡ polyester fiber brushed layer, 100 ~ 150g / ㎡ flame retardant latex layer mixed with phosphorus compound, and 200 ~ 400g / ㎡ polyethylene coating layer, but i The development of alternative technology is urgent due to the concentration of sulfuric acid, a raw material of industrial phosphoric acid, in a specific region (China), unstable production and supply and demand, and ii) the use of flame retardants mixed with latex. The cost of the product is increased because the anti-rust measures must be taken together.

The use of flame retardant powders also increases the cost of flame retardant treatment of carpets. Other flame retardant resin compositions include lower alkyl groups, phenyl group flame retardant styrene resin compositions containing alkylphenyl groups, polyester resin compositions in which a polyester resin is coated with sodium antimonate coated with a brominated flame retardant and a polyester-polyether block copolymer. Although these resins are known, they are not used as materials for automotive floors and carpets.

The present invention is to provide a floor carpet for automobiles and a method of manufacturing the same flame retardancy of the carpet having a polyester fiber brushed and latex layer. The present invention is to provide a car floor carpet and a method of manufacturing the same for improving the flame retardancy by suppressing the combustion activity because the nonwoven fabric attached to the latex layer as a bamboo without using a flame retardant. The present invention seeks to provide a method for producing a floor carpet for automobiles which is easy to process. The present invention seeks to provide an automotive floor carpet that is provided at low cost. The present invention seeks to provide an automotive floor carpet in which the adhesive layer of the nonwoven fabric also serves as a polyethylene coating layer. The present invention seeks to provide an automotive floor carpet which is not accompanied by the problem of rust generation.

This invention is demonstrated in detail according to an accompanying drawing of an Example.

1 is a layer structure diagram of a floor carpet for a conventional vehicle. The floor carpet 10 is composed of a 600-800 g / m 2 polyester fiber brushed layer 11, a 100-150 g / m 2 latex layer 12, and a 200-400 g / m 2 polyethylene coating layer 13.

The polyethylene coating layer 13 is obtained by applying hot melt polyethylene to the bottom surface of the latex layer 12 on which the brush layer 11 is fixed and hardened. The polyethylene is given by a coating method or a spray method by a roll coder. In order to apply the coating layer to the bottom of the carpet by spraying, the carpet is set on the cooling roll so that the bottom of the carpet is roughened, sprayed hot melt polyethylene is applied to the carpet bottom by spraying, and the polyethylene roll is passed through the cooling roll. Harden.

The present invention is an automotive floor carpet having a flame retardancy improved by comprising a latex layer supporting a fiber raising layer, a nonwoven fabric layer formed of the latex layer's porridge, and an adhesive layer bonding the nonwoven fabric layer to the latex layer. .

In FIG. 2, a layer structure of the inventive floor carpet for the present invention is cited. In FIG. 2, the car floor carpet having improved flame retardancy includes a 600-800 g / m 2 polyester fiber brushed layer 11 and a 100-150 g / m 2 latex layer 12, and a nonwoven layer of the latex layer 12. (15), the nonwoven fabric was composed of a polyethylene adhesive layer 14 attached to the latex layer.

 In the present invention, the sheet nonwoven fabric 15 is bonded to the latex layer 12, as described above, and the nonwoven fabric improves flame retardancy by suppressing combustion activities of the latex layer and brushed layer. In the present invention, the adhesive layer 14 serves as a coating layer of the latex layer 12, and a conventional independent coating layer is omitted.

The nonwoven fabric constituting the nonwoven fabric layer is a nonwoven fabric of 20 ~ 60g / ㎡,

The nonwoven fabric of the present invention is a polypropylene thermal bond nonwoven fabric, a polypropylene spunbond nonwoven fabric, a polypropylene melt blown nonwoven fabric, a nonwoven fabric in which at least two layers of polypropylene melt blown nonwoven fabric and polypropylene spunbond are heat-bonded, polyethylene nonwoven fabric, nylon Non-woven fabric, polyester non-woven fabric, non-woven fabric made by mixing at least one of bicomponent yarn mixed with polypropylene and polyethylene, polypropylene yarn, polyethylene yarn, viscose yarn, polyester yarn and nylon yarn, airlaid nonwoven fabric, air through nonwoven fabric, It is a nonwoven fabric selected from spunlace nonwoven fabric and cotton yarn nonwoven fabric.

The adhesive layer 14 is a polyethylene adhesive layer 14 of 200 ~ 400g / ㎡.

This invention will be further clarified by the description of the manufacturing method of attaching the nonwoven fabric to the carpet bottom.

3 is an apparatus diagram for explaining the manufacturing method of the present invention.

In the manufacturing method of the present invention, the step of transporting the car floor seat carpet 10 for the vehicle is supported on the guide rolls (21, 22) to expose the latex layer to the cooling rolls (23, 24),

Applying a polyethylene hot melt 14a to the adhesive layer 14 on the surface of the latex layer in the transfer process in the sprayer 14b installed at the inlet of the cooling rolls 23 and 24;

Supplying a nonwoven fabric 15 between the cooling rolls 23 and 24,

The supplied nonwoven fabric 15 was bonded to the latex layer 12 by an adhesive layer 14 and simultaneously cooled on a cooling roll 23 to form a stable bond.

As such, the present invention attaches the nonwoven fabric supply roll 25 to a facility for giving a coating to the latex layer of the carpet, thereby adhering the nonwoven fabric to the latex layer of the carpet with minimal cost. The carpet thus obtained is not mixed with the flame retardant, but the nonwoven fabric attached to the latex layer porridge suppresses the combustion activity of the latex layer and the brushed layer, thereby improving the flame retardancy of the carpet.

Example 1

Transferring the car floor seat carpet (10) for supporting the cooling rolls (23, 24) to the cooling rolls (23, 24) in which the latex layer is supported on the guide rolls (21, 22) to the surface, the inlet of the cooling rolls (23, 24) Imparting a polyethylene hot melt 14a to the surface of the latex layer during the transfer process as an adhesive layer 14 in the sprayer 14b installed in the sprayer 14b, and supplying a long fiber polyethylene nonwoven fabric 15 between the cooling rolls 23 and 24. The nonwoven fabric 15 is attached to the latex layer by a hot melt polyethylene adhesive layer 14 applied to the surface of the latex layer, and is cooled on a cooling roll 23 to form a stable bond. (15) for automobiles having a 650 g / m 2 polyester fiber brushed layer, a 120 g / m 2 latex layer, a 300 g / m 2 polyethylene adhesive layer, and a 40 g / m 2 nonwoven layer adhered to the latex layer Floor carpet Prepared.

Example 2

Specimens were made for the flame retardant test and the combustion test was carried out to obtain a result (combustion rate 75 mm / min combustion) complying with the flame retardant specification of Table 4.

Table 4. Flame Retardant Specifications

 Item  standard  Psalter  100 mm, 400 mm  Burning speed  Combustion below 80mm / min

As described above, the present invention improved the flame retardancy of the carpet having a brushed polyester fiber and the latex layer, and improved the flame retardancy by suppressing the combustion activity since the nonwoven fabric was attached to the latex layer without using the flame retardant. Provided is a simple, low cost, non-woven adhesive layer serves as a polyethylene coating layer, and does not involve the problem of rust generation, provides a floor carpet for automobiles.

Claims (5)

In the provision of a fiber raising layer and a latex layer which supports a fiber raising layer, the automotive flow which improved the flame retardance comprised by the nonwoven fabric layer which adhere | attaches with the hide of the said latex layer, and the adhesive layer which adhere | attaches the said nonwoven fabric layer to the said latex layer. Oh carpet. The method of claim 1, Fiber brush layer is 600 ~ 800g / ㎡ polyester fiber brush layer, The latex layer is 100 ~ 150g / ㎡ latex layer, The nonwoven fabric is an automotive floor carpet with improved flame retardancy, characterized in that non-woven nonwoven fabric of 20 ~ 60g / ㎡. The floor carpet for automobiles according to claim 1, wherein the adhesive layer is 200 to 400 g / m 2 polyethylene adhesive layer. The floor carpet of claim 3, wherein the adhesive layer is used as a protective coating layer of the latex layer. Transporting the car floorsheet carpet 10 for supporting the cooling rolls 23 and 24 with the latex layer exposed to the guide rolls 21 and 22 so as to be exposed, Applying a polyethylene hot melt 14a to the adhesive layer 14 on the surface of the latex layer in the transfer process in the sprayer 14b installed at the inlet of the cooling rolls 23 and 24; Supplying a nonwoven fabric 15 between the cooling rolls 23 and 24, The supplied nonwoven fabric 15 is bonded to the latex layer 12 by the adhesive layer 14 and at the same time cooled on the cooling roll 23 to form a stable adhesive Method for producing a floor carpet for automobiles improved flame resistance.

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