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CN-122013502-A - Flame-retardant carpet fabric and preparation method thereof

CN122013502ACN 122013502 ACN122013502 ACN 122013502ACN-122013502-A

Abstract

The invention discloses a fabric for a flame-retardant carpet and a preparation method thereof in the technical field of functional textile materials, wherein the fabric is prepared by mixing deionized water, a wetting penetrating agent, amino functional zirconium hydrogen phosphate, microencapsulated red phosphorus, waterborne polyurethane, boron-silicon-zinc hybrid sol and a thickening agent to prepare flame-retardant slurry; and then dipping the carpet base cloth into the slurry, padding, pre-baking and high-temperature baking to finally prepare the finished product. The amino functional zirconium hydrogen phosphate is prepared by synthesizing zirconium hydrogen phosphate by a hydrothermal method, then carrying out surface modification by using a silane coupling agent, and preparing the boron-silicon-zinc hybrid sol by a sol-gel process from zinc salt, boric acid and silane. The carpet fabric prepared by the method has excellent flame retardant property and durability, and the flame retardant functional layer on the surface of the carpet fabric is firmly combined and can resist repeated washing.

Inventors

  • CHEN FANGLIN
  • ZHANG KEZHI
  • Bai Jinna

Assignees

  • 天津金海星新材料有限公司

Dates

Publication Date
20260512
Application Date
20260205

Claims (10)

  1. 1. The preparation method of the flame-retardant carpet fabric is characterized by comprising the following steps of: S1, adding 35-65 parts of deionized water and 0.8-2.5 parts of fatty alcohol polyoxyethylene ether into a stirrer, sequentially adding 6-14 parts of amino functionalized alpha-zirconium hydrogen phosphate and 7-13 parts of microencapsulated red phosphorus under continuous stirring, adding 16-24 parts of aqueous polyurethane and 11-19 parts of boron-silicon-zinc hybrid sol, stirring and mixing, and adding 0.25-0.75 part of polyacrylic thickener to obtain flame retardant slurry; s2, dipping the carpet base cloth into the flame-retardant slurry to obtain padded wet cloth, sending the padded wet cloth into a hot air oven, pre-drying at 105-115 ℃ to obtain pre-dried cloth, transferring the pre-dried cloth to a high-temperature baking machine, baking at 165-175 ℃, cooling and coiling.
  2. 2. The method of producing a flame retardant carpet tile according to claim 1, wherein in step S1, the viscosity of the flame retardant slurry is 2000-3000 mPa-S.
  3. 3. The method of producing a flame retardant carpet tile according to claim 1, wherein in step S2, the baking time is 2 to 3 minutes at 165 to 175 ℃.
  4. 4. The method for preparing a flame retardant carpet tile according to claim 1, wherein the method for preparing the amine group functionalized alpha-zirconium hydrogen phosphate comprises: A1, dissolving zirconium oxychloride octahydrate in hydrochloric acid to obtain a zirconium solution, dropwise adding a phosphoric acid aqueous solution into the zirconium solution under stirring to obtain a mixed solution, transferring the mixed solution to a high-pressure reaction kettle, carrying out hydrothermal crystallization at 195-205 ℃, naturally cooling, and centrifuging to obtain a precipitate, washing the precipitate with water and ethanol, and drying at 78-82 ℃ to obtain crystalline alpha-zirconium hydrogen phosphate; a2, dispersing crystalline alpha-zirconium hydrogen phosphate in deionized water, dropwise adding an absolute ethanol solution of 3-aminopropyl triethoxysilane to react at 60-80 ℃ under stirring to obtain a reaction mixture, centrifuging the reaction mixture to obtain a precipitate, washing the precipitate with ethanol, and drying at 78-82 ℃.
  5. 5. The method of producing a flame retardant carpet tile according to claim 4, wherein in step A1, the time for hydrothermal crystallization at 195-205 ℃ is 24-48 hours.
  6. 6. The method of producing a flame retardant carpet tile according to claim 4, wherein in step A2, the reaction time of the dropwise addition of the anhydrous ethanol solution of 3-aminopropyl triethoxysilane is 4 to 6 hours.
  7. 7. The method for preparing a flame retardant carpet tile according to claim 1, wherein the method for preparing the boron-silicon-zinc hybrid sol comprises: B1, dissolving zinc nitrate hexahydrate in absolute ethyl alcohol to obtain zinc nitrate solution, dissolving boric acid and 3-aminopropyl triethoxysilane in a mixed solvent consisting of absolute ethyl alcohol and deionized water to obtain mixed solution, and dropwise adding the mixed solution into the zinc nitrate solution under stirring at room temperature to obtain a reaction mixture; B2, placing the reaction mixture in an oil bath at 68-72 ℃ for stirring reaction to obtain sol, cooling the sol to room temperature, adding acetylacetone, and continuously stirring.
  8. 8. The method of claim 7, wherein in step B1, the volume ratio of absolute ethyl alcohol to deionized water is 4:1.
  9. 9. The method of producing a flame retardant carpet tile according to claim 7, wherein in step B2, the stirring reaction is carried out for a period of 5 to 10 hours.
  10. 10. A flame retardant carpet tile, characterized in that it is produced according to the method for producing a flame retardant carpet tile according to any one of claims 1-9.

Description

Flame-retardant carpet fabric and preparation method thereof Technical Field The invention relates to the technical field of functional textile materials, in particular to a flame-retardant carpet fabric and a preparation method thereof. Background Carpet is an important component of upholstery and flooring materials, and its widespread use is accompanied by continued concern over fire safety. Most of common carpet fabrics are inflammable or flammable materials, are easy to burn and spread rapidly once contacting a fire source, and release a large amount of heat and toxic smoke to form serious fire hidden danger. Therefore, the carpet fabric is subjected to effective flame retardant treatment, and is a necessary requirement for improving the safety level of public buildings, vehicles and houses. The existing flame-retardant realization path mainly can be divided into two main categories, namely, firstly, adding a flame retardant in the fiber production process and secondly, carrying out surface finishing after the fabric is finished. The former may affect the spinning process and the basic properties of the fiber, while the latter relies on dipping, coating, etc. techniques to apply a flame retardant functional layer to the surface of the fabric. However, whatever the route, how to achieve high efficiency, durability of flame retardant efficacy, and compatibility with application object physical properties is always a core challenge for the industry. There are respective significant limitations to the various flame retardant systems currently used in the textile field. Part of traditional inorganic flame retardants need extremely high addition amount to reach the flame retardant standard, which often leads to hardening of the hand feeling of the fabric and impaired mechanical strength, and the components have poor compatibility with the polymer matrix and are easy to migrate and fall off. Some highly effective halogen-based flame retardants are severely limited in their application due to environmental and health risks. Although the phosphorus-nitrogen halogen-free flame retardant of great interest performs well in many situations, the brush durability of its flame retardant function is often insufficient when dealing with carpet products that require frequent cleaning. A further problem is that many flame retardant treatments combine the flame retardant components with the fibers by physical attachment or simple mixing only, with weak interfacial forces. This combination may be effective in the dry state, but after actual use conditions such as rubbing, washing, etc., the flame retardant component is extremely vulnerable to loss, resulting in rapid deterioration of performance. Furthermore, the flame retardant effect of a single mechanism tends to be frustrating when dealing with complex combustion processes, and it is difficult to form a strong and multi-layered fire barrier. Aiming at the bottleneck, the latest research trend focuses on building a novel flame-retardant system through material design and interface engineering. Among them, layered inorganic compounds are valued for their potential physical barrier and catalytic char formation properties, but how to improve their compatibility and binding force with organic matrices is critical. Meanwhile, the sol-gel technology provides possibility for constructing a continuous and compact nano protection layer on the surface of the fiber, but the performance of a single-component network is still improved. Therefore, various flame-retardant elements are finely integrated through a chemical method, so that the flame-retardant elements exert synergistic effects in different links such as gas phase inhibition, condensed phase carbonization, heat insulation protection and the like, and the whole flame-retardant functional layer is firmly anchored on the fiber substrate by utilizing a strong chemical bonding strategy, so that the flame-retardant functional layer becomes an important direction for breaking through the limitation of the prior art. Under the background, the invention aims to develop a carpet fabric solution with excellent flame retardant property, excellent durability and good practicability, and the core of the carpet fabric solution is that two key functional components are innovatively prepared and are combined firmly through the synergistic effect of the two key functional components by an optimized process. Disclosure of Invention The invention aims to provide a fabric for a flame-retardant carpet and a preparation method thereof, which solve the technical problems that the existing flame-retardant carpet is poor in washing fastness caused by weak combination of a flame retardant and fibers, and the hand feeling and physical properties of the fabric are seriously damaged by excessively adding a filler for pursuing a flame-retardant effect. The invention realizes the above purpose through the following technical scheme: A preparation method o