BR112020017638A2 - NON-WOVEN FABRIC - Google Patents

Abstract

non-woven fabric. In order to provide a non-woven fabric that exhibits high flame-retardant performance and thermal insulation properties, a non-woven fabric that includes a non-melting fiber that has a high temperature shrinkage rate of 3% or less is manufactured and a thermal conductivity in accordance with the iso22007-3 (2008) standard of 0.060 w / m · k or less and a thermoplastic fiber b which has a loi value in accordance with the jis k 7201-2 (2007) standard of 25 or more and has a density of more than 50 kg / m3 and less than 200 kg / m3.

Description

NON-WOVEN FABRIC Technique Field

[001] The present invention relates to a non-woven fabric. Background of the Invention

[002] “Conventionally, in applications necessary to exhibit flame retardancy, a method has been adopted in which a chemical that has a flame retardant effect is mixed with polyester, nylon, cellulose-based fibers in the raw yarn stage and a method in which a chemical that has a flame retardant effect is applied to polyester, nylon and cellulose-based fibers in post-processing.

[003] As a flame retardant, halogen-based chemicals and phosphorus-based chemicals are generally used, but the replacement of halogen-based chemicals with phosphorus-based chemicals has recently occurred due to environmental legislation. However, there are some phosphorus-based chemicals that do not achieve the flame retardant effect of conventional halogen-based chemicals.

[004] As a method for transmitting greater flame retardancy, there is a method in which a polymer that exhibits high flame retardancy is combined. For example, paper formed by a composite of a flame resistant yarn and a polyphenylene sulphide fiber (Patent Document 1) and felt formed by a composite of a flame resistant yarn and a polyphenylene sulphide fiber (Document of Patent 2) are known.

Prior Art Documents

[005] Patent Documents

[006] Patent Document 1: International Publication No. 2017/6807

[007] Patent Document 2: Japanese Patent Publication Submitted to Public Inspection No. 2013-169996 Short Description of the Invention Problems to be solved by the Invention

[008] However, conventional flame retardant performance is obtained by testing how difficult it is to burn the material itself or whether the material can protect from the flames of the burner when being heated from a surface with the use of a burner prescribed in the JIS standard , and it cannot be said that conventional flame retardant performance is sufficient to prevent the spread of fire when the material is exposed to raging flames like a real fire for a long time or when other flammable substances are present. In the method described in Patent Document 1, the flame can be shielded by the burner prescribed in the JIS standard, but in a case where the temperature of the heating source is higher or flammable substances that ignite due to temperature increase are in close contact with paper, the ignition occurs when the temperature in the back that is not reached by the flame rises rapidly and exceeds the ignition point of the fuels that are in close contact with the back that is not reached by the flame as the polyphenylene sulfide carbonized by flame transmits heat and, therefore, there is room for improvement. Patent Document 2 discloses felt formed by a composite of flame resistant wire and polyphenylene sulfide fiber, but the felt density is low and there is a possibility that flammable substances will ignite when the air heated by the burner escapes. from the spans of the felt, the ambient temperature on the opposite side that is not reached by the flame rises rapidly and the flammable substances are disposed on the opposite side that is not reached by the flame.

[009] “Consequently, an object of the present invention is to provide a non-woven fabric that exhibits high performance of flame protection and thermal insulation property.

Solutions to Problems

[010] The present invention adopts the following means to solve the above problems.

(1) A non-woven fabric that includes a non-melting A fiber that has a high temperature shrinkage rate of 3% or less and a thermal conductivity in accordance with ISO22007-3 (2008) of 0.060 W / mK or less and a thermoplastic fiber B which has a LOI value in accordance with JIS K 7201-2 (2007) of 25 or more, where the density of the non-woven fabric is more than 50 kg / m? and less than 200 kg / m ?.

(2) The non-woven fabric according to (1), in which the fiber content without melting A is 15% to 70%, by weight.

(3) The non-woven fabric according to (1) or (2), which includes a fiber C, except for the non-melting fiber A and the thermoplastic fiber B, at 20% by weight or less.

(4) The non-woven fabric according to any one of (1) to (3), wherein the non-melting fiber A is a flame resistant fiber or a meta-aramid based fiber.

(5) The non-woven fabric according to any one of (1) to (4), where the thermoplastic fiber B is a fiber formed by a resin selected from the group consisting of fused anisotropic polyester, retardant polyalkylene terephthalate flame retardant, polyacrylonitrile butadiene flame retardant styrene, flame retardant polysulfone, polyether ether ketone, polyether ketone ketone, polyether sulfone, polyarylate, polyarylene sulfide, polyphenylsulfone, polyetherimide, polyamide-imide and any mixture of these resins.

(6) The non-woven fabric according to (5), wherein the thermoplastic fiber B is a fiber containing a sulfur atom of 15%, by weight, or more.

(7) The non-woven fabric according to any one of (1) to (6), in which the density of the non-woven fabric is 70 to 160 kg / m ?.

Effects of the Invention

[011] The non-woven fabric of the present invention has the configuration described above and, therefore, exhibits high performance of flame protection and thermal insulation property.

Brief Description of the Figures

[012] Figure 1 is a diagram to explain a combustion test to assess flame protection performance and thermal insulation properties. Realizations of the Invention

[013] The present invention is a non-woven fabric that includes a non-melting A fiber that has a high temperature shrinkage rate of 3% or less and a thermal conductivity in accordance with ISO22007-3 (2008) of 0.060 W / mK or less and a thermoplastic fiber B that has a LOI value according to JIS K 7201-2 (2007) of 25 or more and has a density of more than 50 kg / m? and less than 200 kg / m ?.

High Temperature Shrinkage Rate

[014] In the present invention, the high temperature shrinkage rate is a numerical value determined by the following equation of LO and L1 obtained as follows: a fiber, which is a raw material for non-woven fabric, is left in a state standard (20ºC, 65% relative humidity) for 12 hours, then a voltage of 0.1 cN / dtex is applied to the fiber, the length LO is measured, the fiber is exposed to an atmosphere of dry heat at 290ºC for 30 minutes, without applying a load to the fiber, sufficiently cooled in the standard state (20ºC, 65% relative humidity), and a tension of 0.1 cN / dtex is applied to the fiber, and the length L1 is measured.

[015] High temperature shrinkage rate = [(LO - L1) / LO] x 100 (%)

[016] The thermoplastic fiber melts when the flame approaches and heat is applied to it, and the fused thermoplastic fiber spreads in a thin film format across the surface of the non-melting (aggregate) fiber. When the temperature rises further, both fibers will eventually be carbonized, but the high temperature shrinkage rate of the non-melting fiber is 3% or less, thus, the proximity of the contact portion of the flame in which the temperature has increased , it is difficult to shrink, the fracture of the non-woven fabric due to the thermal stress generated between the low temperature portion that is not in contact with the flame and the high temperature portion, hardly occurs, and as a result, the flame can be shielded by a long time. It is preferred that the high temperature shrinkage rate is low from this point on, but the high temperature shrinkage rate is preferably -5% or more, since the non-woven fabric fracture due to thermal stress is caused even when the fiber does not shrink, but expands significantly by heat. Among others, the rate of shrinkage at high temperature is preferably 0% to 2%. Thermal Conductivity

[017] Thermal conductivity is a numerical value that indicates the ease of conducting heat, and a small thermal conductivity means that the temperature increase in the unheated portion is small when the material is heated from a surface. A material that has a thermal conductivity of 0.060 W / m-K or less, measured by a method in accordance with ISO22007-3 (2008) and using a felt that has a weight per unit area of 200 g / m? and a thickness of 2 mm (density: 100 kg / m?), measured by a method in accordance with standard JIS L 1913 (2010) as a test body, hardly transmits heat, the temperature rise on the opposite side that does not it is heated can be suppressed when the material is formed in a non-woven fabric and heated from a surface, and the possibility that the flammable substance will ignite decreases, even when a flammable substance is disposed on the opposite side. It is more preferable that the thermal conductivity is lower, but its upper limit is about 0.020 W / m-K for available fiber materials.

LOI Value

[018] OvalorLO! Is the percentage by volume of the minimum amount of oxygen needed to sustain the combustion of a substance in a mixture of nitrogen gas and oxygen, and it can be said that it is less likely to burn since the LOI value is more high. Therefore, a thermoplastic fiber that has a LOI value in accordance with JIS K 7201-2 (2007) of 25 or more is unlikely to burn, and even if the thermoplastic fiber catches on fire, the fire is extinguished immediately when the fire source is thermoplastic fiber is separated from the source, and a carbonized film is usually formed on the slightly burnt portion, and this carbonized portion can prevent the spread of fire. It is more preferred that the LOI value is higher, but the upper limit of the LOI value for currently available substances is around 65. Ignition Temperature

[019] The ignition temperature is the spontaneous ignition temperature, measured by a method in accordance with JIS K 7193 (2010). Fusion point

[020] The melting point is a value measured by a method in accordance with JIS K 7121 (2012). The melting point refers to the peak melting temperature value when heating is carried out at 10 ° C / min.

Non-Fusion Fiber A

[021] In the present invention, non-fused fiber A refers to a fiber that does not liquefy, but retains its shape when exposed to a flame, and those that do not liquefy or ignite at a temperature of 800ºC are preferred and those that do not liquefy or ignite at a temperature of 1,000ºC or more are more preferable. Examples of the non-melting fiber that have the high temperature shrinkage rate in the range prescribed in the present invention include a flame resistant fiber, a meta-aramid based fiber and a glass fiber. Flame-resistant fiber is a fiber obtained by submitting a fiber selected from an acrylonitrile-based fiber, a pitch-based fiber, a cellulose-based fiber, a phenol-based fiber or as a raw material for a resistant treatment the flame. These can be used alone or two or more of these can be used at the same time. Among these, flame resistant fibers, of which the high temperature shrinkage rate is low and carbonization proceeds due to the oxygen protection effect of the film formed by the thermoplastic fiber B, which will be described later, at the moment of the flame contact, and heat resistance at a high temperature is further improved, they are preferred. Among the various flame resistant fibers, a flame resistant fiber based on acrylonitrile is most preferably used as the fiber that has a small specific gravity, flexibility and excellent flame retardation, and this flame resistant fiber is obtained by heating and oxidation of an acrylic fiber as a precursor in high temperature air. Examples of commercially available products include Pyromex (trademark) (manufactured by Toho Tenax Co ,, Ltd.), as well as flame resistant PYRON fiber (trademark) (manufactured by Zoltek companies, Inc.) which is used in the Examples and Examples Comparatives that will be described later. Generally, a meta-aramid-based fiber has a high shrinkage rate at high temperature and does not satisfy the high-temperature shrinkage rate prescribed in the present invention, but a meta-aramid-based fiber of which the shrinkage rate at high temperature is adjusted to be in the range of the high temperature shrinkage rate prescribed in the present invention by a suppression treatment can preferably be used. The non-melting fiber preferably used in the present invention is used in a method in which the non-melting fiber is used alone or is combined with a different material, and the length of the fiber is preferably in the range of 30 to 120 mm, more preferably in a range from 38 to 70 mm. When the length of the fiber is in the range of 38 to 70 mm, it is possible to obtain a non-woven fabric using a needle-piercing method or a water-jet interlacing method and it is easy to combine with a different material. The thickness of the single fiber of the non-fused fiber is also not particularly limited, but the fineness of the single fiber is preferably in the range of 0.1 to 10 dtex from the point of view of the carding-through process.

[022] When the content of the non-melting fiber in the non-woven fabric is very low, the function as an aggregate is insufficient and, therefore, the mixing ratio of the non-melting fiber in the non-woven fabric is preferably 15%, in mass, or more, more preferably 20%, by mass, or more. The upper limit is preferably 70%, by weight, or less, and more preferably 60%, by weight, or less, from the point of view of the productivity and strength of the nonwoven fabric. Thermoplastic Fiber B

[023] The fibratermoplastic B used in the present invention is one of which the LO! is in the range prescribed in the present invention and the melting point is less than the ignition temperature of the non-melting fiber A, and specific examples thereof include fibers formed from thermoplastic resins selected from the group consisting of fused anisotropic polyester, terephthalate of flame retardant polyalkylene, polyacrylonitrile butadiene flame retardant styrene, flame retardant polysulfone, polyether etherketone, polyether ketone ketone, polyether sulfone, polyarylate, polyarylene sulfide, polyphenyl sulfone, polyetherimide, any of these polyamide-imide and any of these. These can be used alone or two or more of these can be used at the same time. Like the LO value! is in the range prescribed in the present invention, combustion of air is suppressed and the polymer is likely to be carbonized. As the melting point is lower than the ignition temperature of the non-melting fiber A, the molten polymer forms a film on the surface of the non-melting fiber A and between the fibers, and the film is further carbonized, thus the effect of oxygen protection is improved, oxidative deterioration of the non-fused A fiber can be suppressed, and the carbonized film has excellent flame protection performance. The melting point of the thermoplastic fiber B is less than the ignition temperature of the non-melting fiber A preferably by 200ºC or more, more preferably 300ºC or more. Among these, polyphenylene sulfide fiber (from now on also referred to as PPS fiber) is more preferred from the point of view of high LOI value, melting point range, and easy availability. Even a polymer whose LOI value is not within the range prescribed in the present invention can preferably be used because it is treated with a flame retardant, as long as the polymer's LOI value after treatment is in the range prescribed in the present invention. Most preferred is PPS, since PPS contains a sulfur atom in the polymer structure or the flame retardant, thus generating sulfuric acid at the time of the thermal decomposition of the polymer or flame retardant, and develops a mechanism for dehydration and carbonization of the polymer substrate, and a sulfur-based flame retardant is preferred if a flame retardant is used. As thermoplastic fiber B, it is preferable to use a fiber containing sulfur atoms at 15%, by weight, or more. Specific examples of these include PPS and polyester, to which a sulfur-based flame retardant is added. The upper limit is preferably 50%, by weight or less, from the point of view of the fiber strength.

[024] The sulfur atom ratio in the present application is determined by raising the temperature of about 10 mg of the sample from room temperature to 800ºC at 10ºC / min, under a condition of air flow, oxidation and decomposition of the thermoplastic fiber with the use of a thermogravimetric analyzer, and quantitatively analyzing sulfur oxide in the decomposition gas by gas chromatography.

[025] The thermoplastic fiber B used in the present invention is used in a method in which the thermoplastic resin is used alone or is combined with a different material, and the length of the fiber is preferably in the range of 30 to 120 mm, more preferably in a range from 38 to 70 mm. When the length of the fiber is in the range of 38 to 70 mm, it is possible to obtain a non-woven fabric using a needle-piercing method or a water-jet interlacing method and it is easy to combine with a different material. The thickness of the single fiber of the thermoplastic fiber B is also not particularly limited, but the fineness of the single fiber is preferably in the range of 0.1 to 10 dtex from the point of view of the carding-passing process.

[026] The PPS fiber preferably used in the present invention is a synthetic fiber formed by a polymer of which the polymer structural unit includes - (CsHa4-S) - as the main structural unit. Typical examples of these PPS polymers include polyphenylene sulfide, polyphenylene sulfone sulfide, polyphenylene ketone sulfide, random copolymers and block copolymers thereof, and any mixtures thereof, etc. As a particularly preferred PPS polymer, a polyphenylene sulfide containing a p-phenylene sulfide unit represented by - (CsH4-S) - as the main structural unit of the polymer preferably at 90% per mol or more is desirable. From the mass point of view, polyphenylene sulfide containing an 80% by weight p-phenylene sulfide unit is desirable, even more preferably at 90% by weight or more.

[027] The PPS fiber preferably used in the present invention is used in a method in which the PPS fiber is used alone or is combined with a different material, and can be in the form of filament or staple fiber. In the case of using PPS fiber in the form of fibers, the fiber length is preferably in the range of 30 to 120 mm, more preferably in the range of 38 to 70 mm. When the length of the fiber is in the range of 38 to 70 mm, it is possible to obtain a non-woven fabric using a needle-piercing method or a water-jet interlacing method and it is easy to combine with a different material. The thickness of the single PPS fiber is also not particularly limited, but the fineness of the single fiber is preferably in the range of 0.1 to 10 dtex from the point of view of the carding-through process.

[028] The method for producing the PPS fiber used in the present invention is preferably a method in which a polymer, which has the aforementioned phenylene sulfide structural unit, is melted at a temperature equal to or higher than its melting point. and spun from a spinner to form a fiber. The spun fiber is a non-pulled PPS fiber, just as it is. Most of the unstretched PPS fibers have an amorphous structure and a large fracture elongation. On the other hand, these fibers are inferior in dimensional stability due to heat and, therefore, unstretched fibers in which the strength and thermal dimensional stability of the fibers are enhanced by hot drawing and orientation after spinning are commercially available. Like PPS fibers, a plurality of PPS fibers such as “TORCON” (registered trademark) (manufactured by TORAY INDUSTRIES, INC.) And “PROCON” (registered trademark) (manufactured by TOYOBO CO ,, LTD.) Are in circulation.

[029] In the present invention, the unstretched PPS fiber and the pulled fiber can be used simultaneously in the range that satisfies the range of the present invention. Instead of the PPS fiber, it is certainly possible to use both a pulled fiber and an un pulled fiber of a fiber that satisfies the range of the present invention simultaneously.

[030] When the mixing ratio of the thermoplastic fibers B in the nonwoven fabric is very low, the thermoplastic fibers do not disperse sufficiently in a film format between the fibers without melting the aggregate and thus the mixing ratio of the fibers thermoplastic B in the non-woven fabric is preferably 10%, by weight, or more, more preferably 20%, by weight, or more. When the mixing ratio of the thermoplastic fiber B is very high, it is likely that the carbonized portion is fragile at the time of flame contact and the flame protection performance decreases, thus, the upper limit of the mixing ratio is preferably 80% , by weight, or less, more preferably 70%, by weight, or less.

Fiber C Except Non-Fusion Fiber A and Thermoplastic Fiber B

[031] A fiber C, except non-fusion fiber A and thermoplastic fiber B, may be contained in the non-woven fabric in order to still provide specific performance. For example, a vinalon fiber, a polyester fiber, except thermoplastic fiber B, a nylon fiber, and the like, can be used in order to enhance the hygroscopic and water-absorbing properties of the non-woven fabric. The mixing ratio of fiber C is not particularly limited, as long as the effect of the present invention is not impaired, and the mixing ratio of fiber C, except non-melting fibers A and thermoplastic fibers B is preferably 20%, by weight , or less, more preferably 15%, by weight, or less. The lower limit in the case of using fiber C is not particularly limited, as long as the desired performance is checked, but the lower limit is generally preferably about 10%, by weight.

[032] The thickness of the non-woven fabric of the present invention is measured by a method in accordance with JIS L 1913 (2010) and is preferably 0.08 mm or more. When the thickness of the non-woven fabric is too thin, sufficient flame protection performance and thermal insulation performance cannot be achieved.

[033] As the morphology of the fibers used in the non-woven fabric of the present invention, the number of corrugations of the fibers is preferably 7 corrugations / 2.54 cm or more, even more preferably 12 corrugations / 2.54 cm or more, in order sufficiently achieve fiber interlacing. The number of undulations in the present invention is measured in accordance with the JIS L 1015 (2000) standard.

[034] The lengths of the short fibers of the non-melting fiber A and of the thermoplastic fiber B are preferably the same in order to obtain a more uniform non-woven fabric. The same length does not have to be exactly the same, and the length of the thermoplastic fiber B can differ by about + 5% from the length of the non-melting fiber A. From this point of view, the length of the fiber of the non-melted fiber melting and the length of the thermoplastic fiber B or fiber C are preferably in a range of 30 to 120 mm, more preferably in a range of 38 to 70 mm.

[035] The non-woven fabric of the present invention is produced by a needle-piercing method, a waterjet interweaving method or the like, using the short fibers above. The structure of the non-woven fabric is not limited, as long as it is in the range prescribed in the present invention, but is it necessary that the density of the non-woven fabric be more than 50 kg / m? and less than 200 kg / m ?, and 55 to 180 kg / m? is preferred, more preferably 70 to 160 kg / m ?, particularly preferably 75 to 160 kg / m ?. The density is calculated by dividing the weight of a 30 cm square sample by the thickness,

measured by a method in accordance with JIS L 1913 (2010).

[036] The density of the nonwoven fabric is important for the nonwoven fabric of the present invention, to exhibit both excellent flame protection performance and thermal insulation property. Heat transmission includes that generated through a solid substance, that generated through a gas, and that caused by radiation. When the density increases, the volume occupied by the fibers that make up the non-woven fabric in the volume of the unit increases and the points of contact between the fibers increase and, thus, the thermal conductivity increases. Specifically, when the density is greater than 200 kg / m?, The heat is likely to be transmitted by the flame-carbonized polyphenylene sulfide and the temperature at the back that is not reached by the flame tends to increase rapidly. On the other hand, when the density is less than 50 kg / m ?, when a surface of the non-woven fabric is heated, the air heated at high temperature tends to escape to the opposite side of the non-woven fabric, the conduction of heat is promoted due to the air flow, and the temperature on the back side that is not reached by the flame tends to increase rapidly. In other words, adjusting the density of the nonwoven fabric to a range of more than 50 kg / m? and less than 200 kg / m ?, PPS fibers properly form a carbonized film to exert a flame protection performance and a thin layer of air is properly maintained in the direction of the thickness of the nonwoven fabric, as a result , the conduction of heat through solid substances and gas is suppressed and excellent thermal insulation properties are exhibited. That is, it is important that the density value is within a certain range. On the other hand, the transmission of heat by radiation is suppressed when the density is high. In other words, the transmission of heat by radiation is suppressed even more the lower the reciprocal of the density. Considering the above, excellent thermal insulation property is obtained by adjusting the sum of the density and the reciprocal of density, that is, (density + (1 / density)) to be in an appropriate range. The degrees of influence of the effect of heat transmission through solid substances, effect of heat transmission through gas, and effect of heat transmission by radiation are different from each other, strictly speaking, therefore, it is necessary to determine experimentally the weighting of each density term and the term (1 / density), but in the range of the present invention, the value of density (kg / m?) + 1 / density (kg / m?) is preferably from 20 to 400, more preferably from 25 to 350, even more preferably 30 to 300 in order to achieve excellent flame protection performance and thermal insulation property. As the thickness of the non-woven fabric that contains this structure increases, the thermal insulation property is proportionally improved.

[037] After the non-woven fabric is produced, the heat adjustment can be performed using a dryer (stenter) or calender in the range prescribed in the present invention. As usual, the gray fabric can be used as is. The setting temperature is preferably a temperature at which the effect of suppressing the rate of shrinkage at high temperature is reached, and is preferably 160 ° C to 240 ° C, more preferably 190 ° C to 230 ° C. Calendering is to adjust the thickness, i.e. the density of the nonwoven fabric, and the speed, pressure and temperature for calendering are not limited as long as a nonwoven fabric that has physical properties in the ranges prescribed in the present invention is obtained.

[038] The nonwoven fabric of the present invention thus obtained is excellent in the performance of flame protection and thermal insulation property, and exerts a fire propagation prevention effect, being particularly combined with a flammable substance, therefore, it is suitable for use in clothing materials, wall materials, floor materials, ceiling materials, cladding materials, and the like, which are necessary to exhibit flame retardancy, and is particularly suitable for use in fireproof protective clothing and materials of preventive coverage of fire propagation for urethane sheet materials and prevention of fire propagation for upholstery of motor vehicles and aircraft.

EXAMPLES

[039] In the following, the present invention will be specifically described based on the Examples. However, the present invention is not limited to these Examples only. Various changes and modifications can be made without departing from the scope of the technique of the present invention. Incidentally, the methods for measuring various properties used in the present Examples are as follows.

Weight per Unit Area

[040] The weight of a 30 cm square sample was measured and expressed in weight per 1 m? (g / m2). Thickness

[041] The thickness was measured in accordance with JIS L 1913 (2010). Performance Evaluation of Flame Protection and Thermal Insulation Property

[042] Soft urethane foam commercially available from Fuji Gomu co ,, Ltd. is cut to a length of 20 cm, a width of 20 cm and a thickness of 20 cm to obtain urethane foam (1). The nonwoven fabric (2) of the present invention is covered on the surface of the urethane foam (1), and the location indicated by (3) in Figure 1 is sewn with a cotton thread to form the sewn portion (3). The sample is heated using a burner (4) for 2 minutes, at a distance of 5 cm from the sample. As a burner (4), the Power Torch RZ-730 manufactured by Shinfuji Burner co., Ltd was used. The flame temperature is adjusted to 1000 degrees using a thermocouple. After 2 minutes of heating, the burner flame was extinguished, and the condition of the non-woven fabric and the internal urethane were observed. A case in which a hole is not formed in the non-woven fabric after 2 minutes of heating is rated as “exhibits flame protection performance” and rating A. A case in which a hole is formed in the non-woven fabric during 2 minutes of heating and the flame reaches the internal urethane foam is rated as

“Does not exhibit flame protection performance” and an F rating. In a case where the burner flame is extinguished after 2 minutes of heating, the sample is cooled to room temperature for 10 minutes, and the internal urethane foam is burned and the fire spreads or the urethane foam is completely burned is rated as “does not exhibit thermal insulation properties” for the urethane foam and F rating. A case where the fire is self-extinguished after the burner flame is extinguished and the foam from urethane remains is rated B, and a case in which the fire is self-extinguished and the weight reduction rate of urethane foam is 5%, by weight, or less, is rated A.

[043] In the following, the terms will be described in the Examples and Comparative Examples below.

Fiber Pulled from PPS Fiber

[044] It was used as a pulled PPS fiber, “TORCON” (registered trademark), product number S371 (manufactured by TORAY INDUSTRIES, INC.) Having a single fiber fineness of 2.2 dtex (diameter: 14 µm) and a cutting length of 51 mm. This PPS fiber has a LO value! 34, a melting point of 284ºC, and a wave number of 11 waves / 2.54 cm. The ratio of sulfur atoms in the fiber was 26.2%, by weight.

Flame Resistant Wire

[045] A 1.7 dtex PYRON flame resistant fiber (manufactured by Zoltek Companies, Inc.) was cut in 51 mm. The high temperature shrinkage rate of PYRON was 1.6%. When PYRON was heated by a method in accordance with JIS K 7193 (2010), ignition was not observed even at 1,000ºC, and the ignition temperature was 1,000ºC. The thermal conductivity was 0.042 W / m-K. The number of waves is 10 waves / 2.54 cm.

Polyethylene Terephthalate Fiber (PET)

[046] It was used as a pulled PET fiber, “-TETORON” (registered trademark) (manufactured by TORAY INDUSTRIES, INC.) Having a single fiber fineness of 2.2 dtex (diameter: 14 µm) and a length of 51 mm cut. This PET fiber has a LOI value of 22 and a melting point of 267ºC. The number of dimples is 17 dimples / 2.54 cm. No sulfur atom was detected in the fiber. Carbon fiber

[047] "TORAYCA" (registered trademark) (manufactured by TORAY INDUSTRIES, INC.) With a diameter of 30 microns cut in 51 mm was used. The thermal conductivity was 8.4 W | Im-K.

Example 1 Manufacture of Nonwoven Fabric

[048] The fiber pulled from PPS fiber and the flame resistant wire were mixed using a skimmer and then mixed with a fan and then passed through a carding machine to make a blanket. The obtained blanket was stacked using a veil bender and formed in felt using a water jet interlacing machine to obtain a non-woven fabric including a fiber pulled from PPS fiber and a flame resistant yarn. The weight ratio of the fiber pulled from PPS fiber to the flame resistant yarn in the non-woven fabric was 60:40, the weight per unit area of the non-woven fabric was 100 g / m ?, and its thickness of 1.21 mm.

Performance Evaluation of Flame Protection and Thermal Insulation Property

[049] The flame did not penetrate the nonwoven fabric for 2 minutes, the internal urethane foam did not catch fire, and the weight reduction rate of the urethane foam was 0.7%, by mass, indicating that the fabric did not fabric exhibited sufficient flame protection performance and thermal insulation property.

Example 2

[050] The weight ratio of the pulled PPS fiber to the flame resistant yarn in the nonwoven fabric was changed to 90:10 in Example 1 to obtain a nonwoven fabric that has a weight per unit area of 100 g / m? and a thickness of 1.53 mm.

[051] The flame did not penetrate the nonwoven fabric for 2 minutes, the internal urethane foam did not catch fire, and the weight reduction rate of the urethane foam was 15.2%, by mass, indicating that the present fabric nonwoven exhibited sufficient flame protection performance and thermal insulation property.

Example 3

[052] The weight ratio of the pulled PPS fiber to the flame resistant yarn in the nonwoven fabric was changed to 30:70 in Example 1 to obtain a nonwoven fabric that has a weight per unit area of 100 g / m? and a thickness of 1.64 mm.

[053] The flame did not penetrate the nonwoven fabric for 2 minutes, the internal urethane foam did not catch fire, and the weight reduction rate of the urethane foam was 1.2%, by mass, indicating that the present fabric nonwoven exhibited sufficient flame protection performance and thermal insulation property.

Example 4

[054] The weight ratio of the pulled PPS fiber to the flame resistant yarn in the nonwoven fabric was changed to 10:90 in Example 1 to obtain a nonwoven fabric that has a weight per unit area of 100 g / m? and a thickness of 1.63 mm.

[055] The flame did not penetrate the nonwoven fabric for 2 minutes, the internal urethane foam did not catch fire, and the weight reduction rate of the urethane foam was 5.6%, by mass, indicating that the present fabric nonwoven exhibited sufficient flame protection performance and thermal insulation property.

Example 5

[056] Has the weight per unit area of non-woven fabric changed to 50 g / m? in Example 1 to obtain a non-woven fabric that is 0.89 mm thick.

[057] Achama did not penetrate the nonwoven fabric for 2 minutes, the internal urethane foam did not catch fire, and the weight reduction rate of the urethane foam was 3.2%, by mass, indicating that the present fabric did not fabric exhibited sufficient flame protection performance and thermal insulation property.

Example 6

[058] Has the weight per unit area of non-woven fabric changed to 120 g / m? in Example 1 to obtain a non-woven fabric that is 1.91 mm thick.

[059] The flame did not penetrate the nonwoven fabric for 2 minutes, the internal urethane foam did not catch fire, and the weight reduction rate of the urethane foam was 0.3%, by mass, indicating that the present fabric nonwoven exhibited sufficient flame protection performance and thermal insulation property.

Example 7

[060] The felting method was changed to needle piercing in Example 1 to obtain a nonwoven fabric including a fiber pulled from PPS fiber and a flame resistant yarn. The weight ratio of the fiber pulled from PPS fiber to the flame resistant yarn in the nonwoven fabric was 60:40, the weight per unit area of the nonwoven fabric was 300 g / m ?, and its thickness of 3.12 mm.

[061] Achama did not penetrate the nonwoven fabric for 2 minutes, the internal urethane foam did not catch fire, and the weight reduction rate of the urethane foam was 0.1%, by mass, indicating that the present fabric did not fabric exhibited sufficient flame protection performance and thermal insulation property.

Example 8

[062] The nonwoven fabric obtained in Example 7 passed through a resin roll-resin roll calender once at room temperature, a linear pressure of 50 N / cm, and a roll rotation speed of 5 m / min to obtain a non-woven fabric that has a weight per unit area of 300 g / m? and a thickness of 1.87 mm.

[063] The flame did not penetrate the nonwoven fabric for 2 minutes, the internal urethane foam did not catch fire, and the weight reduction rate of the urethane foam was 0.1%, by mass, indicating that the present fabric nonwoven exhibited sufficient flame protection performance and thermal insulation property.

Example 9

[064] A PET fiber was mixed except the PPS fiber pulled fiber and the flame resistant yarn and the mixing ratio, by weight, of the PPS fiber pulled fiber to the flame resistant yarn and the PET fiber was set to 40:40:20 in Example 1 to obtain a nonwoven fabric that has a weight per unit area of 100 g / m? and a thickness of 1.30 mm.

[065] The flame did not penetrate the nonwoven fabric for 2 minutes, the internal urethane foam did not catch fire, and the weight reduction rate of the urethane foam was 4.7%, by mass, indicating that the present fabric nonwoven exhibited sufficient flame protection performance and thermal insulation property.

Comparative Example 1

[066] A 1.7 dtex flame resistant PYRON fiber (manufactured by Zoltek Companies, Inc.), a 1.0 dtex PPS pulled fiber, “-TORCON” "(registered trademark) (manufactured by TORAY INDUSTRIES, INC.) And a 3.0 dtex PPS untagged fiber “TORCON” (registered trademark) (manufactured by TORAY INDUSTRIES, INC.), Were each cut in 6 mm and these flame resistant fibers, un pulled fibers of PPS fiber, and PPS fiber pulled fibers were prepared at a weight ratio of 40:30:30 (ie, PPS fiber flame resistant yarn = 40:60). These were dispersed in water to prepare a dispersion. Wet paper was made from the dispersion using a handmade paper machine. The wet paper was heated and dried at

110ºC for 70 seconds using a rotary dryer and subsequently heated and pressed once for each side at a linear pressure of 490 N / cm and a roller rotation speed of 5 m / min a total of two times by adjusting the temperature of surface of the iron roll at 200ºC to obtain a non-woven fabric. Did the obtained non-woven fabric have a weight per unit area of 100 g / m? and a thickness of 0.15 mm.

[067] The flame did not penetrate the non-woven fabric for 2 minutes, but the present non-woven fabric ignited from the internal urethane foam after 1 minute and 30 seconds of heating, and the urethane foam was completely burned in 10 minutes after the burner flame is extinguished.

Comparative Example 2

[068] Has the weight per unit area of non-woven fabric changed to 50 g / m? and its thickness was changed to 10 mm in Example 7 to obtain a nonwoven fabric.

[069] The flame did not penetrate the non-woven fabric for 2 minutes, but the present non-woven fabric ignited from the internal urethane foam after 1 minute of heating, and the urethane foam was completely burned within 10 minutes after burner flame is extinguished.

Comparative Example 3

[070] A carbon fiber was used instead of the flame resistant yarn and the ratio of the PPS fiber pulled to the carbon yarn was set to 40:20 in Example 7 to obtain a non-woven fabric that has a weight per unit of area of 100 g / m? and a thickness of 1.89 mm.

[071] The flame did not penetrate the non-woven fabric for 2 minutes, but the present non-woven fabric ignited from the internal urethane foam after 1 minute and 50 seconds of heating, and the urethane foam was completely burned in 10 minutes after the burner flame is extinguished.

TABLE 1

2: et g E8E | Ee, 8 i | ss É | s; faithful dogs E | es $ i | ges 8 <8tSS |. 38423 H 2 & £ o; "5 1890! 2/8 2 £ E fe, .t gs | 1.8 | It is 58 fans E) ã Sããs Sã 5 i Pr Ho give 15º 3) $ g | E, 8 | t38 | det, “5/82) E | It is if | 38º8º

FA TA AAA | 2.8 | 28 | 5st ã ê | 16 | 36 | 6 and lg <siit | gives | 8 | e | ée |) SS: gtE = 2s $ 38 | 2c5l8, E z ca g 8º 8 and SRTA: s til E 2 gg un 8E Ss a) 2 Et E, É ds | is | 5 | À «aus os ES ae | it's ll SS: 38 | 355 | 35 3 8 | <Sbgs | <& E 3 [E E | sd El & = & 28. Yes | 5: | 285 | ss <stisb | hey 3 33] 8th | E DA Te 7 1 ig 8 E 3; ê di se | és ds 6 ess "sss 18 | 2,8 | E 58 | 3Eg | 36 <E8SS | oxt z $ vs E IS HA à | és E Es = e -” 2 ss E É E Ls FH ss Es | ss over there] 3 Es | és 3 É $ |) 2 E jo £ s | 2 if 8 be É 83 | g8 8. | Ss | 8 | 8% E, £ 8d] give | gise iss cos ie igidl dio | di; 3bs | 32º | EST 2 Es 8º 82 98] (3 sas IRIBNRISDA): | ê Dome [==

Industrial Applicability

[072] The present invention is effective in preventing the spread of fire, is suitable for use in clothing materials, wall materials, floor materials, ceiling materials, cladding materials, and the like, which are necessary to exhibit fire retardation. flame, and is particularly suitable for use in fireproof protective clothing and preventive fire propagation cover materials for urethane sheet materials and fire propagation prevention for automotive vehicle and aircraft upholstery.

Description of Reference Signs 1: Urethane foam 2: Non-woven fabric 3: Stitched portion 4: Burner

Claims (7)

Claims 1. NON-WOVEN FABRIC, characterized by comprising a non-melting A fiber that has a high temperature shrinkage rate of 3% or less and a thermal conductivity in accordance with the IS022007-3 (2008) standard of 0.060 W / mK or less and a thermoplastic fiber B which has a LOI value in accordance with JIS K 7201-2 (2007) of 25 or more, where the density of the non-woven fabric is more than 50 kg / m? and less than 200 kg / m ?. 2. FABRIC according to claim 1, characterized in that the fiber content without melting A is 15% to 70%, by weight. 3. FABRIC according to any one of claims 1 to 2, characterized in that it comprises a fiber C, except for the non-melting fiber A and the thermoplastic fiber B, at 20%, by weight, or less. 4. FABRIC according to any one of claims 1 to 3, characterized in that the non-melting fiber A is a flame resistant fiber or a fiber based on meta-aramid. 5. FABRIC according to any one of claims 1 to 4, characterized in that the thermoplastic fiber B is a fiber formed by a resin selected from the group consisting of anisotropic fused polyester, flame retardant polyalkylene terephthalate, retarding polyadrylene butadiene styrene flame retardant, flame retardant polysulfone, polyether ether ketone, polyether ketone ketone, polyether sulfone, polyarylate, polyarylene sulfide, polyphenylsulfone, polyetherimide, polyamide-imide and any mixture of these resins. 6. TISSUE according to claim 5, characterized in that the thermoplastic fiber B is a fiber containing a sulfur atom at 15%, by weight, or more. 7. FABRIC according to any one of claims 1 to 6, characterized in that the density of the non-woven fabric is 70 to 160 kg / m? º.