CN107761369A - 布帛的制造方法 - Google Patents

布帛的制造方法 Download PDF

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Publication number
CN107761369A
CN107761369A CN201710670855.9A CN201710670855A CN107761369A CN 107761369 A CN107761369 A CN 107761369A CN 201710670855 A CN201710670855 A CN 201710670855A CN 107761369 A CN107761369 A CN 107761369A
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China
Prior art keywords
cloth
silk
coating
manufacture method
fluorine system
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Granted
Application number
CN201710670855.9A
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English (en)
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CN107761369B (zh
Inventor
林里惠
大原弘平
大石贵之
福井龙也
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Honda Motor Co Ltd
TB Kawashima Co Ltd
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Honda Motor Co Ltd
TB Kawashima Co Ltd
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Publication of CN107761369A publication Critical patent/CN107761369A/zh
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Abstract

本发明提供一种具有优异的防污性以及阻燃性的布帛的制造方法。本发明的布帛的制造方法的特征在于,包括如下工序:(a)在将聚酯系布帛浸渍于包含第一氟系疏水疏油剂的处理液而使其包含处理液之后,对该布帛进行干燥;(b)使用含有第二氟系疏水疏油剂以及阻燃剂的涂覆用组成物对所述布帛的一方的面进行涂覆;以及(c)利用65~90℃的温水对形成有涂层的所述布帛进行清洗。

Description

布帛的制造方法
技术领域
本发明涉及一种具备阻燃性以及防污性的布帛的制造方法。
背景技术
车辆、船舶、航空器等的内部装饰所使用的布帛(例如机动车等交通工具的座位、车门衬里等的装饰构件所使用的布帛)要求阻燃性,同时由于难以洗涤、清洁,因此要求较高的防污性。
作为防污处理,已知对布帛的表面进行疏水、疏油涂覆,作为阻燃处理,已知对布帛的背面进行阻燃涂覆。然而,若对布帛实施疏水、疏油涂覆,则存在布帛的质感变差(变硬)这一问题。另外,若对布帛实施阻燃处理,则存在防污性容易降低这一问题。
尤其是,在机动车等交通工具长时间暴露于夏季的阳光的情况下,车内的温度有时上升到80℃左右,但作为氟系疏水疏油剂的效果而相对于80℃附近的液体的疏水疏油性容易降低,因此存在难以在这样的高温下维持较高的防污性这一问题。
作为即便在高温下也发挥优异的阻燃性和疏水性的布帛,在日本特开2004-76202号公报中公开了表面由阻燃剂和硅氧烷聚合物覆盖的布帛,但未充分研究相对于油的防污性。
发明内容
发明要解决的课题
本发明的课题在于,解决上述的问题,提供一种具备优异的防污性以及阻燃性的布帛。
用于解决课题的方案
本发明人为了解决所述课题而反复深入研究,其结果是,在使聚酯系布帛含浸有氟系疏水疏油剂之后,在该布帛的单面形成包含氟系疏水疏油剂以及阻燃剂的涂层,并进一步利用65~90℃的温水来清洗涂层形成后的布帛,由此成功地解决了上述课题,从而完成了本发明。
即,本发明涉及一种布帛的制造方法,其特征在于,包括如下工序:
(a)在将聚酯系布帛浸渍于包含第一氟系疏水疏油剂的处理液而使其包含处理液之后,对该布帛进行干燥;
(b)使用含有第二氟系疏水疏油剂以及阻燃剂的涂覆用组成物对所述布帛的一方的面进行涂覆;以及
(c)利用65~90℃的温水对形成有涂层的所述布帛进行清洗。
若使聚酯系布帛含浸有氟系疏水疏油剂,则能够达到所期望的防污性,但在为了进一步赋予阻燃性而在布帛上形成阻燃背涂层时,观察到防污性的降低。
与此相对,在本发明中,在布帛的一方的面(尤其是布帛的背面)上形成含有氟系疏水疏油剂以及阻燃剂的涂层(工序b),而且之后进行过水(工序c),由此成功地同时具有优异的防污性和阻燃性。
在所述工序(b)中,优选的是,以使所述涂层所包含的第二氟系疏水疏油剂在布帛的每单位面积上的含量为0.5~4.0g/m2、且所述涂层所包含的阻燃剂在布帛的每单位面积上的含量为25~60g/m2的方式进行涂覆。
另外,优选的是,所述涂覆用组成物包含从丙烯酸系树脂、聚氨酯系树脂以及聚酯系树脂中选择的粘结剂,以使所述涂层所包含的粘结剂在布帛的每单位面积上的含量为15~35g/m2的方式进行工序(b)的涂覆。
作为所述阻燃剂的优选的例子,可举出向20℃的水溶解的溶解度为4.0%以下的磷系阻燃剂。
另外,也可以是,本发明的方法在所述工序(a)之后且所述工序(b)之前还包括对所述布帛进行清洗的工序。
另外,也可以是,本发明的方法在所述工序(c)之后还包括向所述布帛的所述一方的面紧贴固定发泡材料片的工序。在单面紧贴固定有发泡材料片的布帛适于用作交通工具的座位等的表皮材料。
发明效果
根据本发明,能够提供一种具有高阻燃性和防污性的布帛。另外,通过本发明的方法而制造出的布帛的质感也优异。
附图说明
图1是表示本发明的布帛的图,(a)示出在聚酯系布帛1的背面侧形成有涂层2的布帛,(b)示出进一步紧贴固定有发泡材料片3的布帛。
图2是说明在实施例2中进行的布帛的质感确认试验的方法的图。
附图标记说明
1 含浸有氟系疏水疏油剂的聚酯系布帛
2 含有氟系疏水疏油剂以及阻燃剂的涂层
3 发泡材料片
具体实施方式
本发明的特征在于,针对含浸有氟系疏水疏油剂的聚酯系布帛,使用包含氟系疏水疏油剂和阻燃剂的组成物对所述布帛的单面进行涂覆,之后进行过水(热水洗)。
即便使布帛含浸氟系疏水疏油剂,若为了进一步赋予阻燃性而在布帛形成阻燃背涂层,则布帛的防污性也降低。另外,即使替代在布帛上形成阻燃背涂层而利用阻燃剂含有处理液对布帛进行浴中加工,也难以对布帛赋予充分的阻燃性,且在该情况下也容易使防污性降低。作为像这样防污性因阻燃处理而降低的理由,认为是在对纤维制品进行阻燃处理时使用的阻燃组成物包含乳化剂、界面活性剂,因此它们有可能对防污性造成不良影响。
另外,存在如下问题:当向阻燃涂覆组成物添加氟系疏水疏油剂而形成阻燃-防污涂层时,虽与单独使用阻燃剂的情况相比防污性得到改善,但依然难以达到稳定的防污性。
与此相对,在本发明中,在布帛的一方的面(尤其是背面)形成包含氟系疏水疏油剂和阻燃剂的涂层,而且之后进行热水洗,由此能够提供防污性和阻燃性这两者优异、而且质感良好的布帛。
在本发明中,“所期望的防污性”是指,如实施例的项目所示,基于JIS L1092的疏水性初始为95分以上,且在实施例的项目所记载的色拉油防污试验中,在83℃、24小时后,在布帛的表面和背面以及软擦巾(soft wipe)上不存在油渍。83℃这一温度是氟系疏水疏油剂的效果容易降低的温度,但就本发明的布帛而言,即使向布帛表面滴下色拉油并在83℃的温度下放置的情况下,油也不会渗入布帛,因此即使沾上由包含油的食品等造成的污渍,也容易去除该污渍。
另外,在本发明中,“所期望的阻燃性”是指,依据由美国联邦机动车安全基准(FMVSS)规定的“内部装饰材料的燃烧性”来进行试验,即便使火焰与布帛接触15秒钟也不着火的情况(N),或者当使火焰与布帛接触时着火,但在火焰超过A标线之后在燃烧距离为101mm以内且燃烧时间为60秒以内灭火的情况。尤其是,优选在所述评价中成为“N”的布帛。
另外,本发明的布帛优选在实施例的项目所记载的摩擦牢固度试验中,在干燥以及湿润试验这两者中均能够达到4级以上。
作为本发明所使用的基布,从容易达到所期望的阻燃性的情况出发,选择聚酯系布帛。
在本发明中,聚酯系布帛是指包含聚酯纤维的布帛,不仅可以是由聚酯纤维单独构成的纺织品、编织物、无纺布,也可以是将聚酯纤维与其他纤维(棉花、羊毛等天然纤维或者聚酰胺、人造丝、丙烯酸类纤维等化学纤维)组合来使用的交织品、交编品等中的任一方。聚酯纤维占据布帛的构成纤维的比例优选为60重量%以上,更优选为70重量%以上,尤其优选为80重量%以上,进一步优选为90重量%以上。尤其优选的布帛是由聚酯纤维构成的厚度为0.2~3.0mm(单位面积重量100~700g/m2)、尤其是厚度为0.4~2.6mm(单位面积重量为200~500g/m2)的布帛。
在本发明中,在对所述聚酯系布帛的单面进行涂覆之前,含浸氟系疏水疏油剂(第一氟系疏水疏油剂)(工序a:防污加工)。氟系疏水疏油剂是指含有烃基中的氢原子的全部或者一部分被氟原子置换而成的全氟烷基的化合物。在本发明中,尤其是,优选使用包含具有全氟烷基的单体的聚合物。作为本发明所能够使用的第一氟系疏水疏油剂,例如可举出从旭硝子株式会社以AsahiGuard-E的名称销售的氟系疏水疏油剂、从日华化学株式会社以NKGUARDS的名称销售的氟系疏水疏油剂。
浸渍处理所使用的第一氟系疏水疏油剂可以是一种,也可以是多种(例如2~3种)。
在本发明的工序a)中,通常可以使用被称作填充(padding)处理或浸压(dip-nip)处理的浸渍处理。例如,调制出含有1.0~5.0重量%的第一氟系疏水疏油剂(固体成分)、更优选含有1.5~3.5重量%的水性处理液,将所述聚酯系布帛浸渍于该处理液(例如2~5分钟),并通过辊(轧液机)等进行挤压,从而能够使布帛整体包含处理液,之后使其干燥,由此能够得到不仅在布帛的表面而且在内部的纤维也附着有第一氟系疏水疏油剂的布帛(含浸有第一氟系疏水疏油剂的布帛)。适当的干燥条件例如是在110~170℃、尤其是120~160℃中干燥1~5分钟左右。
通过该防污加工而含浸于布帛的第一氟系疏水疏油剂的量可以根据处理液中的氟系疏水疏油剂的浓度和挤压率来计算。对于干燥处理后的布帛所包含的第一氟系疏水疏油剂的含浸量而言,在布帛的每单位面积上优选为2.0g/m2~8.0g/m2,更优选为3.0g/m2~7.0g/m2,尤其优选为4.0g/m2~6.5g/m2
也可以在基于所述工序a)的防污加工之后,进行清洗(还原清洗或基于温水的清洗)处理。还原清洗一般是针对由高染料浓度染色后的纤维制品、为了除去成为色移等的原因的多余的染料而进行的,通常将纤维制品放入包含连二亚硫酸盐和氢氧化钠的水溶液中,并以80℃左右(例如65~90℃、更优选为70~85℃)的温度进行清洗的工序。然而,以高染料浓度染色后的布帛即便在染色后进行还原清洗,也由于所述防污加工而容易从布帛渗出染料,因此在防污加工后布帛的摩擦牢固度降低(容易产生色移)。因此,对于以高染料浓度染色后的布帛的情况下,优选在防污加工后也进行还原清洗。另外,虽存在质感因所述防污加工而变差(变硬)的倾向,由于质感会因清洗而得以改善,因此对于不存在摩擦牢固度的问题的布帛(以低染料浓度染色后的布帛),也优选在防污加工后进行清洗处理。需要说明的是,对于以低染料浓度染色后的布帛的情况下,可以不进行还原清洗,而是以温水(例如65~90℃、更优选为70~85℃)进行清洗。在还原清洗的情况以及温水清洗的情况下,均可以将清洗时间设置在1分钟~60分钟的范围内,例如为15~40分钟左右。
需要说明的是,能够以布帛的色移的容易度为标准来判断在防污加工后的清洗工序中选择还原清洗和温水清洗中的哪一方(以高染料浓度染色后的布帛容易发生色移,以低染料浓度染色后的布帛不容易发生色移)。作为以高染料浓度染色后的布帛的例子,可举出黑、蓝、红、紫、深灰、深藏青、深绿等的以约5%owf以上的染料浓度染色后的布帛,作为以低染料浓度染色后的布帛的例子,可举出白、浅灰、淡茶色、奶油色等的以小于约5%owf的染料浓度染色后的布帛。更具体而言,对于防污加工后的布帛,在干燥、湿润试验这两者中摩擦牢固度为4.0级以上的情况下,能够判断为无需进行还原清洗,在小于4.0级的情况下,能够判断为需要进行还原清洗。摩擦牢固度的测定依据JIS L0849(针对摩擦的染色牢固度试验方法)。
在所述工序a)之后、以及任意地进行所述清洗处理并使布帛干燥(例如在110~170℃、尤其是120~160℃中干燥1~5分钟左右)之后,在其单面形成包含第二氟系疏水疏油剂以及阻燃剂的涂层(工序b)。
作为在工序b)中使用的第二氟系疏水疏油剂,能够使用作为工序a)的第一氟系疏水疏油剂而在之前叙述过的疏水疏油剂,可以使用与第一氟系疏水疏油剂相同的疏水疏油剂,也可以使用不同的疏水疏油剂,可以仅使用一种疏水疏油剂,也可以一并使用多个种类的疏水疏油剂。
另外,在工序b)中使用的阻燃剂优选是向20℃的水溶解的溶解度为4%(4g/水100g)以下的磷系阻燃剂。作为磷系阻燃剂,例如可举出从由膦酸酯类、磷酸酰胺类、磷酸酯酰胺类、芳香族磷酸酯类、含卤素磷酸酯类、无机聚磷酸盐、磷酸二铵等构成的组中选择出的阻燃剂。尤其优选有机磷系阻燃剂。作为优选的阻燃剂的一例,可举出膦酸酯系阻燃剂和/或磷酸密胺。
用于形成该涂层的组成物优选包含1.0~6.0重量%、更优选包含1.5~5.0重量%、尤其优选包含2.0~4.0重量%(均是氟系疏水疏油剂的固体成分重量相对于涂覆组成物的固体成分重量的合计的比例)的第二氟系疏水疏油剂,优选包含25~75重量%、更优选包含40~70重量%、尤其优选包含50~65重量%(均是阻燃剂的固体成分重量相对于涂覆用组成物的固体成分重量的合计的比例)的阻燃剂。
另外,优选以如下方式进行工序b)的涂覆:使所述涂层所包含的第二氟系疏水疏油剂的含量在布帛的每单位面积上为0.5~4.0g/m2、更优选为0.7~3.5g/m2、尤其优选为1.0~3.0g/m2的方式、且所述涂层所包含的阻燃剂的含量在布帛的每单位面积上为25~60g/m2、更优选为28~55g/m2、尤其优选为30~50g/m2
另外,布帛所含浸的第一氟系疏水疏油剂与涂层所包含的第二氟系疏水疏油剂的合计量在布帛的每单位面积上优选为2.5~10.0g/m2、更优选为4.0~9.5g/m2、尤其优选为5.0~9.0g/m2
用于形成本发明的涂层的组成物包含用于将氟系疏水疏油剂、阻燃剂附着(固定)于布帛的粘结剂。作为优选的粘结剂,可举出聚酯系树脂、丙烯酸系树脂、聚氨酯系树脂。在重视阻燃性的情况下,优选使用聚酯系树脂,在重视成本、质感的情况下,优选使用丙烯酸系树脂。
作为所述聚酯系树脂、丙烯酸系树脂、聚氨酯系树脂,可以使用作为通常的布帛用涂覆组成物的粘结剂而使用的市售的聚酯系树脂、丙烯酸系树脂、聚氨酯系树脂。
尤其是,各粘结剂优选是柔软的类型,对于丙烯酸系树脂,优选Tg=-30℃~-45℃,对于聚氨酯系树脂,优选最低造膜温度(MFT)为0℃~5℃。
另外,所述涂覆用组成物也可以包含增稠剂。作为增稠剂,可以使用丙烯酸系增稠剂、聚氨酯缔合型增稠剂等。所述增稠剂向布帛附着的附着量通常为0.5~5.0g/m2左右。
所述涂覆用组成物的粘度优选为20000~70000mPa·s左右,尤其优选为35000~55000mPa·s左右。需要说明的是,在本说明书中,涂覆用组成物的粘度是指,使用B型粘度计(BH型),在测定温度为20℃、转子为No.6、转速为10rpm的条件下从开始旋转起30秒后测定的粘度。
所述涂覆用组成物朝向布帛的涂布可以使用刮刀涂布机、逗号涂布机、棒式涂布机、模涂机、接触辊式涂布机、凹版涂布机等来进行。另外,将涂覆用组成物涂布于布帛之后的干燥条件例如可以设为在110~170℃、尤其是120~160℃中干燥2~5分钟左右。
所述涂层所包含的粘结剂的含量在布帛的每单位面积上为15~35g/m2左右(尤其是18~30g/m2左右)。在增稠剂为丙烯酸系树脂、聚氨酯系树脂的情况下,优选使粘结剂与增稠剂树脂的合计的含量处于所述范围。
在粘结剂的含量过少的情况下,难以将氟系疏水疏油剂、阻燃剂充分固定于布帛,在含量过多的情况下,有可能使质感变硬。
另外,布帛上的涂层的量(干燥后)在布帛的每单位面积上优选为45~90g/m2、更优选为50~85g/m2
本发明的特征在于,在工序b)中将涂层形成于布帛的单面之后,进行用温水清洗布帛的工序(工序c)。通常,若用温水清洗疏水疏油剂含浸后的布帛、涂覆后的布帛,则可预想到药剂的流出所引起的效果的减弱,因此不会在药剂含浸后、涂覆后清洗布帛,但在本发明中即使在涂层形成后进行热水洗,也能够维持所期望的阻燃性,且能够提高防污性。另外,通过该热水洗工序,能够使布帛的质感良好(柔软)。由工序c)引起的防污性的提高被认为是涂层中的界面活性剂、乳化剂中的至少一部分或者全部在热水洗工序中被洗去的缘故,质感的提高被认为是在清洗时存在于纤维之间的涂覆剂、疏水疏油剂被解放而使纤维自由度提高的缘故。
需要说明的是,通过工序b)而形成的涂层包含第二氟系疏水疏油剂,因此若采用小于65℃的温水,则布帛不会充分地润湿,无法充分得到通过温水清洗实现的防污性改善效果。另一方面,若采用超过90℃的温水,则涂层中的第二氟系疏水疏油剂、阻燃剂也被除去的可能性高,防污性、阻燃性有可能降低。
因而,在工序c)中,优选用65~90℃(更优选为70~90℃、尤其优选为75~85℃)的温水清洗所述布帛。清洗时间优选为1~30分钟左右,更优选为5~25分钟左右,尤其优选为10~20分钟左右来进行清洗。
说明工序c)的优选的一例时,例如作为连续清洗机,能够使用如下装置一边不断地供给新的温水(例如以5~15L/分钟的供给速度)一边进行连续清洗,所述装置具有多个(例如4~6槽)在每槽中能够保持2000~4000升的温水的槽,在各槽的内部上下交替地设置有辊,在各槽内能够使布帛在展布状态下朝斜上、斜下行进(例如使宽度约为100cm~200cm的布帛在展布的状态下以长度约为15~30m/槽的方式朝斜上、斜下行进)。清洗时间能够通过布帛的移动速度来调整。例如,在采用利用五个槽对100m(每槽中20m)的布帛进行清洗的五槽连续清洗机的情况下,若以5m/分钟移动布帛,则清洗时间为20分钟,若以10m/分钟移动布帛,则清洗时间为10分钟。另外,在各槽的水变脏的情况下,优选将温水全部更换(例如,每当清洗600~1000m的布帛时,将各槽的温水全部更换)。这样,通过在展布状态下清洗布帛,能够柔软地清洗布帛,因此容易抑制从布帛流出药剂。另外,通过在展布状态下进行清洗,也能够防止布帛产生褶皱。
在所述热水洗工序后,对布帛进行干燥。优选的干燥条件例如是在110~170℃中、尤其在120~160℃中干燥1~5分钟左右。
在本发明中,也可以在所述工序c)之后,在所述布帛的一方的面(具有涂层的面)上紧贴固定发泡材料片。作为发泡材料片的例子,可举出厚度为2.0~10mm的聚氨脂泡沫塑料(厚聚氨酯等)。由这样的布帛和发泡材料片构成的层压复合体优选用作机动车等交通工具的座位(通常由聚氨酯系缓冲材料构成的成形品)的表皮材料。
作为将发泡材料片紧贴固定于布帛的单面的方法,例如可举出火焰层压加工,在该火焰层压加工中,使用气体燃烧器使发泡材料片的单面的表层熔化,并使其熔接于形成有所述涂层的布帛的单面(涂层上)。
除此之外,本发明的方法中,也可以在工序a)之前包括染色和/或阻燃加工工序。例如,可以在放入有分散染料的浴中进行布帛的染色处理,或者可以在放入有有机磷系阻燃剂的浴中进行布帛的阻燃加工。需要说明的是,若浴中阻燃加工时的阻燃剂过多,则布帛的防污性有可能降低。因此,就浴中加工时的阻燃剂(固体成分)的放入量而言,作为owf(相对于布帛的重量的放入量),优选为0.2~2.0%owf,尤其是优选为0.4~1.3%owf左右,作为向布帛的附着量,优选为0.5~4.0g/m2,尤其是优选为1.0~3.0g/m2左右。
另外,也可以在同一浴中进行染色和阻燃。除此之外,在染色时以高染料浓度(约5%owf以上)对布帛进行了染色的情况下,也可以在染色后进行还原清洗。
以下,举出比较例以及实施例来更详细地说明本发明,但本发明并不限定于实施例。
【实施例】
[实施例1]
通过表1所示的工序而对聚酯布帛(聚酯100%:单位面积重量360g/m2)进行处理。
在表1的工序中,在染色处理时(工序1),与黑色的分散染料(以按固体成分换算计为约9.8%owf的方式添加)一并添加0.84%owf(固体成分换算)的从大京化学株式会社以ビゴールFV-6010的商品名销售的磷酸酰胺系阻燃剂,并与染色同时地进行浴中阻燃加工。
另外,在基于dip-nip的防污加工(工序4)中,作为第一氟系疏水疏油剂,使用从旭硝子株式会社以AsahiGuardE系列的名称销售的氟系疏水疏油剂与从日华化学株式会社以NKGUARDS的名称销售的氟系疏水疏油剂的混合物,在包含2.44重量%(固体成分换算)的第一氟系疏水疏油剂的水分散液中浸渍聚酯布帛(150℃、2分30秒),接下来,利用轧液机以3.0kgf/cm2的压力进行了挤压(pic-up率为60%)。
对于涂覆(工序8以及工序9),分别使用以粘度处于45000~55000mPa·s的范围的方式调整出的涂覆用组成物,并利用刮刀涂布机对布帛的背面进行涂覆。
在涂覆中使用的阻燃剂(工序8以及工序9)是从丸菱油化工业株式会社以NonnenCP-104GKO的名称销售的有机磷系阻燃剂(作为粘结剂包含丙烯酸系树脂而以膦酸酯系阻燃剂(向20℃的水溶解的溶解度为4.0%以下)为主要成分的非卤素系阻燃涂覆剂)。
涂覆所使用的第二氟系疏水疏油剂(工序8)是从日华化学株式会社以NKGUARDS的名称销售的氟系疏水疏油剂。
在涂层形成后的清洗工序(工序11)中,使用五槽连续清洗机,向各槽放入3000升的80℃的温水,通过设置于槽的内部的上下辊而在每槽中使约20m的布帛在展布状态下以速度为6.5m/分钟向斜上、斜下行进,并且以10L/分的速度向槽内不断供给新的80℃的温水,同时进行约15分钟的清洗。
针对通过表1所示的工序制造出的加工布帛,之后通过以下的方法对摩擦牢固度、布帛的阻燃性能、色拉油防污性、疏水性进行试验。另外,在加工布帛的背面侧(形成有涂层的面)热熔厚度3.0mm的厚聚氨酯片而形成层压复合体(通过在使用气体燃烧器使厚聚氨酯片的单面的表层熔融后将其紧贴固定于加工布帛的背面侧的火焰层压加工来形成),之后测定层压复合体的阻燃性能。
<摩擦牢固度>
依据JIS L0849(针对摩擦的染色牢固度试验方法),对各加工布帛进行了干燥试验(DRY)和湿润试验(WET)。对于污染的判定,使用污染用灰度级(JIS L0805)进行了1~5级的判定。将4级以上判定为合格。
<阻燃性能>
依据美国联邦机动车安全基准(FMVSS:Federal Motor-Vehicle SafetyStandard)所规定的“内部装饰材料的燃烧性”进行试验,判定了阻燃性能。
将即便火焰与布帛(加工布帛单独或层压复合体)接触15秒钟也没有着火的情况(N)、或者将火焰与布帛接触时着火、但在火焰越过A标线后在燃烧距离为101mm以内且燃烧时间为60秒以内灭火的情况(101mm/分钟以下)设为合格。
<色拉油防污试验>
作为试验片,从各试样(加工布帛)准备一张约10×10cm方形尺寸的试验片来进行试验。在托盘上铺设软擦巾(Elleair Prowipe),载置试验片(在进行了涂覆的情况下,以使涂覆面(背面)朝下的方式载置于软擦巾上),在试验试样上,利用玻璃吸管将色拉油以试样上的各滴的直径成为约5mm的方式或将0.05ml的油滴于各部位的方式向五处滴下。
将托盘放入吉尔烘箱的83℃之中,静置24小时。24小时后取出托盘,观察在试验片表面上色拉油滴下部位是否湿润(是否产生油渍),另外观察背面和软擦巾是否存在色拉油的油渍。将试验试样的表面和背面、以及铺设于下方的软擦巾不存在油渍的试样设为合格。
<疏水性>
在由JIS L1092 6.2规定的装置中,将切割为20cm×20cm的大小的试验片以不产生褶皱的方式安装于试验片保持框。
将蒸馏水或离子交换水250ml放入漏斗,向试验片上(表侧)散布。
接着,针对每个保持框而将试验片从台上卸下,在保持框的一端处水平地保持,使试验片的表侧向下而使另一端暂时较轻地与硬物接触并进一步使之旋转180°,与之前同样地进行操作而去掉多余的水滴。
在安装有保持框的状态下对试验片的湿润的状态进行评分。
0分:表面(散布水的面)以及背面整体显现出湿润的试验片
50分:表面整体显现出湿润的试验片
70分:表面的一半显现出湿润,显现一小处一小处的湿润浸透布的状态的试验片
80分:在表面上显现一小处一小处的水滴状的湿润的试验片
90分:表面不湿润,但显现小的水滴的附着的试验片
95分:表面不存在湿润,显现小的水滴略微附着的试验片
100分:在表面上不存在湿润、水滴的附着的试验片
将初期为95点以上的情况设为合格。
表1示出加工工序和加工布帛的性能,表2示出通过dip-nip工序、涂覆工序而向基布附着的各成分的固体成分量(单位:g/m2)。
【表1】
表1.加工工序以及加工布帛的性能
【表2】
表2.通过dip-nip或涂覆向基布赋予的药剂的固体成分吊(单位:g/m2)
基布:单位面积重量360g/m2的聚酯布帛
如表1所示,坯料(仅进行了染色及浴中阻燃处理和还原清洗的布帛)的摩擦牢固度和阻燃性能良好,但色拉油防污试验的结果差。与此相对,在进一步以包含氟系疏水疏油剂的水分散体对所述布帛进行了dip-nip加工的情况下(布帛No.1),色拉油防污试验以及疏水试验良好,但阻燃性以及摩擦牢固度降低。与此相对,在dip-nip处理后进行了还原清洗的情况下(布帛No.2),摩擦牢固度的DRY和WET均改善到4级,但阻燃性能仍不充分。在进一步对dip-nip后的布帛形成有阻燃背涂层的情况下(布帛No.3),阻燃性能为“N”,但在色拉油防污试验中确认到了油渍的产生。接着,在dip-nip后的布帛上形成有阻燃防污背涂层的情况下(布帛No.4),阻燃性能为“N”,但在色拉油防污试验中观察到试验片上存在油渍的部位和不存在油渍的部位这两方,防污试验的结果出现波动。
与此相对,在布帛的背面形成了包含氟系疏水疏油剂以及阻燃剂的涂层之后进行了热水洗的布帛(No.5以及No.6)在加工布帛的摩擦牢固度、阻燃性、色拉油防污试验、疏水试验以外,还在层压品的阻燃性方面均达到了所期望的特性。
[实施例2]
为了确认工序6以及工序11的清洗给布帛的质感带来的影响,进行了以下的实验。
将坯料、No.1、No.2、No.4以及No.5的布帛分别切割为20cm×20cm的大小,并测定了在纵向以及横向上以背面侧(涂层形成侧)朝外侧进行对折时的样本的高度h(mm)(参照图2)。弯折高度h的值小意味着布帛柔软而质感良好,弯折高度h的值越高则布帛越硬而质感越差。将测定结果示于表3中。
【表3】
表3.质感评价试验的结果
如表3所示,与在防污加工后没有进行清洗的布帛(No.1)相比,在防污加工后进行了清洗的布帛(No.2)的h的平均值小,质感得到改善。需要说明的是,在本实施例中利用高染料浓度(约10%owf)对布帛进行了染色,因此在防污加工后进行了还原清洗,但在利用低染料浓度(小于约5%owf)对布帛进行了染色的情况下,也可以替代还原清洗而进行热水洗(65~90℃),由此也能够得到同样的质感的改善效果。
另外,与在涂层形成后没有进行热水洗的布帛(No.4)相比,在涂层形成后进行了热水洗的布帛(No.5)的h的平均值小,质感得到改善。尤其是,No.2(无涂层)与No.5(有涂层)的布帛的h的平均值相同,因此确认到:通过涂层形成后的热水洗,使得因涂层形成而恶化的布帛的质感被改善为与涂层形成前相同的程度。
根据以上的实验可知,为了得到具有所期望的阻燃性、防污性的布帛,在含浸有氟系疏水疏油剂的布帛的单面形成有包含氟系疏水疏油剂以及阻燃剂的涂层之后进行热水洗的做法是有效的。另外,确认到涂层形成后的热水洗也改善布帛的质感。进一步知晓为了使布帛的质感更加良好,优选在含浸氟系疏水疏油剂的工序之后(且在涂层形成之前)也进行清洗工序(还原清洗或热水洗)。
产业上的可利用性
根据本发明,能够防止果汁、咖啡等饮料、食品所包含的水分、油分所造成的污渍,能够提供即使在80℃附近的温度下放置24小时后油分也不会渗入并透过背面的聚酯系布帛。另外,本发明的布帛也具有优异的阻燃性能和优异的质感,因此适合用作机动车等交通工具的内部装饰用布帛。

Claims (7)

1.一种布帛的制造方法,其特征在于,
所述布帛的制造方法包括如下工序:
(a)在将聚酯系布帛浸渍于包含第一氟系疏水疏油剂的处理液而使其包含处理液之后,对该布帛进行干燥;
(b)使用含有第二氟系疏水疏油剂以及阻燃剂的涂覆用组成物对所述布帛的一方的面进行涂覆;以及
(c)利用65℃~90℃的温水对形成有涂层的所述布帛进行清洗。
2.根据权利要求1所述的布帛的制造方法,其中,
所述布帛的所述一方的面为布帛的背面。
3.根据权利要求1或2所述的布帛的制造方法,其中,
以使所述涂层所包含的第二氟系疏水疏油剂在布帛的每单位面积上的含量为0.5g/m2~4.0g/m2、且所述涂层所包含的阻燃剂在布帛的每单位面积上的含量为25g/m2~60g/m2的方式进行工序(b)的涂覆。
4.根据权利要求1至3中任一项所述的布帛的制造方法,其中,
所述涂覆用组成物包含从丙烯酸系树脂、聚氨酯系树脂以及聚酯系树脂中选择的粘结剂,以使所述涂层所包含的粘结剂在布帛的每单位面积上的含量为15g/m2~35g/m2的方式进行工序(b)的涂覆。
5.根据权利要求1至4中任一项所述的布帛的制造方法,其中,
所述阻燃剂是向20℃的水溶解的溶解度为4.0%以下的磷系阻燃剂。
6.根据权利要求1至5中任一项所述的布帛的制造方法,其中,
所述布帛的制造方法在所述工序(a)之后且所述工序(b)之前还包括对所述布帛进行清洗的工序。
7.根据权利要求1至6中任一项所述的布帛的制造方法,其中,
所述布帛的制造方法在所述工序(c)之后还包括向所述布帛的所述一方的面紧贴固定发泡材料片的工序。
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