CN107761370A - 布帛及其制造方法 - Google Patents

布帛及其制造方法 Download PDF

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Publication number
CN107761370A
CN107761370A CN201710670876.0A CN201710670876A CN107761370A CN 107761370 A CN107761370 A CN 107761370A CN 201710670876 A CN201710670876 A CN 201710670876A CN 107761370 A CN107761370 A CN 107761370A
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China
Prior art keywords
cloth
silk
coating
fire retardant
fluorine system
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Granted
Application number
CN201710670876.0A
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English (en)
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CN107761370B (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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    • D06M13/08—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with non-macromolecular organic compounds; Such treatment combined with mechanical treatment with halogenated hydrocarbons
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Abstract

本发明提供具有优异的防污性以及阻燃性的布帛及其制造方法。本发明的布帛的特征在于，在含浸有氟系疏水疏油剂的聚酯系布帛(1)的一面具有第一涂层(2)和第二涂层(3)，所述第一涂层(2)是包含氟系疏水疏油剂的层，所述第二涂层(3)是包含阻燃剂的层，布帛(1)的一侧为第一涂层(2)，第一涂层(2)中的与布帛相反的一侧为第二涂层(3)。

Description

布帛及其制造方法
技术领域
本发明涉及具备阻燃性以及防污性的布帛及其制造方法。
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的涂层(第一涂层)，并进一步在其上形成包含阻燃剂的涂层(第二涂层)，由此成功地解决了上述课题，从而完成了本发明。
即，本发明的布帛的特征在于，
在含浸有氟系疏水疏油剂的聚酯系布帛的一方的面上具有第一涂层和第二涂层，
所述第一涂层是包含氟系疏水疏油剂的层，所述第二涂层是包含阻燃剂的层，
布帛侧为第一涂层，第一涂层中的与布帛相反的一侧为第二涂层。
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，将疏水疏油涂层和阻燃涂层从布帛侧起按照疏水疏油涂层、阻燃涂层的顺序设置，由此成功地同时具有优异的防污性和阻燃性。
而且，也可以在所述布帛的所述一方的面(涂层形成面)上紧贴固定有发泡材料片。在单面紧贴固定有发泡材料片的布帛适合用作交通工具的座位等的表皮材料。另外，本发明的布帛与发泡材料片良好地紧贴固定，布帛与发泡材料片不容易剥离。
优选的是，所述第一涂层所包含的氟系疏水疏油剂在布帛的每单位面积上的含量为0.5～5.0g/m2。
另外，也可以是，所述第一涂层还包含阻燃剂。
作为本发明的布帛的优选的例子，可举出如下布帛：在该布帛中，所述第一涂层所包含的氟系疏水疏油剂以及阻燃剂在布帛的每单位面积上的含量分别为0.5～3.0g/m2以及0g/m2，所述第二涂层所包含的阻燃剂在布帛的每单位面积上的含量为30～60g/m2。
另外，作为另一优选的例子，可举出如下布帛：在该布帛中，所述第一涂层所包含的氟系疏水疏油剂以及阻燃剂在布帛的每单位面积上的含量分别为2.5～5.0g/m2以及25～45g/m2，所述第二涂层所包含的阻燃剂在布帛的每单位面积上的含量为15～35g/m2，第一涂层所包含的阻燃剂的含量比第二涂层所包含的阻燃剂的含量多。
另外，本发明涉及一种布帛的制造方法，其是能够制造所述布帛的方法，其中，包括如下工序：
在将聚酯系布帛浸渍于包含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；
在所述布帛的一方的面上形成包含氟系疏水疏油剂的第一涂层；以及
在所述第一涂层上形成包含阻燃剂的第二涂层。
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，对于本发明的布帛，在向涂层形成面紧贴固定有发泡材料片(厚聚氨酯片等)时，不易产生布帛与发泡材料片间的剥离。
附图说明
图1是表示本发明的布帛的图，图1的(a)示出在聚酯系布帛1的背面侧具有第一涂层2和第二涂层3的布帛，图1的(b)示出进一步紧贴固定有发泡材料片4的布帛。
附图标记说明：
1 含浸有氟系疏水疏油剂的聚酯系布帛
2 第一涂层
3 第二涂层
4 发泡材料片
具体实施方式
本发明的特征在于，含浸有氟系疏水疏油剂的聚酯系布帛在其单面(尤其是背面)具有氟系疏水疏油涂层和阻燃涂层，氟系疏水疏油涂层配置于布帛与阻燃涂层之间。
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，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，另外，在布帛的涂覆面侧紧贴固定有厚聚氨酯等的发泡材料片时，存在布帛与发泡材料片容易剥离这一问题。
与此相对，在本发明中，能够提供如下的布帛：通过在布帛的一面形成包含氟系疏水疏油剂的第一涂层，在该第一涂层上形成包含阻燃剂的第二涂层，从而防污性和阻燃性这两者优异，而且与发泡材料片的剥离强度高。需要说明的是，在颠倒阻燃涂层、疏水疏油涂层的位置而按照布帛、阻燃涂层、疏水疏油涂层的顺序层叠的情况下，不仅无法得到所期望的防污性，与发泡材料片的剥离强度也降低。
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(softwipe)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。
另外，在实施例的项目所记载的方法中，优选的是，在将发泡材料片热熔层压于布帛单面(具有涂层的面)时，在实施例的项目所记载的剥离强度试验中，能够达到1.0N/cm以上的剥离强度。
本发明的布帛的特征在于，如上所述，在含浸有氟系疏水疏油剂的聚酯系布帛的一面上，包含氟系疏水疏油剂的第一涂层、包含阻燃剂的第二涂层从布帛侧按照第一涂层、第二涂层的顺序层叠，这样的布帛可以通过如下的本发明的方法来制造，所述本发明的方法包括将聚酯系布帛浸渍于包含氟系疏水疏油剂的处理液之后进行干燥的工序、在该布帛的一面(尤其是背面)形成包含氟系疏水疏油剂的第一涂层的工序、以及在所述第一涂层之上形成包含阻燃剂的第二涂层的工序。
以下，更具体地说明本发明的结构。
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双层涂覆之前，使布帛含浸氟系疏水疏油剂(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)。
在本发明中，含浸有氟系疏水疏油剂的布帛是指，不仅在布帛的表面附着有氟系疏水疏油剂、而且在内部的纤维也附着有氟系疏水疏油剂的布帛。
作为使聚酯系布帛含浸氟系疏水疏油剂的方法，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，由此能够得到含浸有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。
也可以在所述浸渍、干燥工序(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。
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)。
在所述防污加工、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，在其一面(尤其是背面)形成包含氟系疏水疏油剂的涂层(第一涂层)。作为第一涂层的氟系疏水疏油剂，可以使用作为在浸渍处理时使用的氟系疏水疏油剂而在前面叙述过的氟系疏水疏油剂，可以使用与在浸渍处理中使用的氟系疏水疏油剂相同的氟系疏水疏油剂，也可以使用不同的氟系疏水疏油剂，可以仅使用一种氟系疏水疏油剂，也可以一并使用多种氟系疏水疏油剂。
用于形成第一涂层的组成物优选包含1.5～9.0重量％、更优选包含2.0～7.0重量％、尤其优选包含2.5～6.0重量％(均是氟系疏水疏油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)的氟系疏水疏油剂。
对于第一涂层所包含的氟系疏水疏油剂的含量而言，在布帛的每单位面积上，优选为0.5g/m2～5.0g/m2，更优选为0.7g/m2～4.0g/m2，尤其优选为0.8g/m2～3.5g/m2。
另外，对于含浸于布帛的氟系疏水疏油剂和涂层所包含的氟系疏水疏油剂的合计量而言，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。
另外，在本发明中，在布帛的一面(尤其是背面)形成有所述第一涂层，在第一涂层之上形成有包含至少一种阻燃剂的第二涂层。第二涂层所能够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。
用于形成第二涂层的组成物优选包含25～75重量％、更优选包含30～70重量％、尤其优选包含35～65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，对于第二涂层所包含的阻燃剂的含量而言，在布帛的每单位面积上，优选为15g/m2～60g/m2，更优选为20g/m2～55g/m2，尤其优选为22g/m2～53g/m2。
另外，也可以设为向所述第一涂层添加阻燃剂而在第一涂层以及第二涂层这两者中包含阻燃剂的结构。通过这样构成，能够对布帛赋予高阻燃性。作为向第一涂层添加的阻燃剂，可以使用作为第二涂层的阻燃剂而在前面叙述过的阻燃剂，可以使用与第二涂层的阻燃剂相同的阻燃剂，也可以使用不同的阻燃剂，可以仅使用一种阻燃剂，也可以一并使用多种阻燃剂。
另一方面，若向第二涂层添加疏水疏油剂，则在将发泡材料片紧贴固定于布帛时的布帛与发泡材料片的剥离强度降低，因此第二涂层优选实质上不包含疏水疏油剂(就第二涂层所包含的疏水疏油剂的含量而言，在布帛的每单位面积上，优选小于0.1g/m2，更优选为0g/m2)。
需要说明的是，若向第一涂层添加阻燃剂，则存在第一涂层的防污效果降低的倾向，因此优选在第一涂层中存在足够量的氟系疏水疏油剂。更具体而言，在向第一涂层添加阻燃剂的情况下，就第一涂层所包含的氟系疏水疏油剂的含量而言，在布帛的每单位面积上，优选成为2.5g/m2以上，更优选为2.8g/m2以上。
而且，若第一涂层所包含的阻燃剂的量过多，则存在防污效果降低的倾向，因此就第一涂层所包含的阻燃剂的量而言，在布帛的每单位面积上，优选为45g/m2以下，尤其优选为40g/m2以下。
在向第一涂层添加了阻燃剂的情况下，即便减少第二涂层所包含的阻燃剂，也能够达到高阻燃性，另外，减少第二涂层所包含的阻燃剂的量关系到第二涂层的厚度的减少、由此实现的发泡材料片紧贴固定时的剥离强度的提高，因此优选使第一涂层所包含的阻燃剂的含量比第二涂层所包含的阻燃剂的含量多。
作为第一涂层包含氟系疏水疏油剂且不包含阻燃剂的情况下的本发明的优选的布帛的例子，可举出如下布帛：在该布帛中，第一涂层所包含的氟系疏水疏油剂的含量在布帛的每单位面积上为0.5～3.0g/m2(更优选为0.8～2.5g/m2)，第二涂层所包含的阻燃剂的含量在布帛的每单位面积上为30～60g/m2(更优选为32～55g/m2)。
另外，作为第一涂层包含氟系疏水疏油剂和阻燃剂这两方的情况下的本发明的优选的布帛的例子，可举出如下布帛：在该布帛中，第一涂层所包含的氟系疏水疏油剂的含量在布帛的每单位面积上为2.5～5.0g/m2(更优选为2.7～4.0g/m2)，第一涂层所包含的阻燃剂的含量在布帛的每单位面积上为25～45g/m2(更优选为30～40g/m2)，第二涂层所包含的阻燃剂的含量在布帛的每单位面积上为15～35g/m2(更优选为20～27g/m2)，第一涂层所包含的阻燃剂的含量比第二涂层所包含的阻燃剂的含量多。
用于形成本发明的第一涂层以及第二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℃的丙烯酸系树脂，对于聚氨酯系树脂，优选最低造膜温度(MFT)为0℃～5℃。
另外，第一涂覆用组成物以及第二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。涂层所包含的所述增稠剂的含量在布帛的每单位面积上通常为0.5～5.0g/m2左右。
所述第一涂覆用组成物以及第二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。
所述第一涂覆用组成物以及第二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，将第一涂覆用组成物或第二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。
第一涂层所包含的粘结剂的含量在布帛的每单位面积上优选为15～80g/m2左右(尤其是20～70g/m2左右)，第二涂层所包含的粘结剂的含量在布帛的每单位面积上优选为10～50g/m2左右(尤其是10～40g/m2左右)。在增稠剂为丙烯酸系树脂、聚氨酯系树脂的情况下，优选粘结剂与增稠剂树脂合计的量处于所述范围。
在粘结剂的量过少的情况下，难以将氟系疏水疏油剂、阻燃剂充分固定于布帛，在量过多的情况下，质感有可能变硬。
另外，布帛上的第一涂层以及第二涂层的量(干燥后)分别在布帛的单位面积上优选为25～85g/m2，双层合计的量优选为80～140g/m2，更优选为90～130g/m2。
需要说明的是，在如上述那样向第一涂层添加阻燃剂的情况下，为了减少第二涂层的量，例如可以使第一涂层的量为40～85g/m2、优选为50～70g/m2，使第二涂层的量为25～50g/m2、优选为30～45g/m2。
另外，对于本发明的布帛而言，也可以在布帛的涂覆面侧(第二涂层上)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第一涂层以及第二涂层的布帛的单面(第二涂层上)。
除此之外，本发明的方法中，也可以在使用所述氟系疏水疏油剂进行的浸渍处理之前包括染色和/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，作为向布帛的含浸量，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)，与黑色或淡茶色的分散染料一并添加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。需要说明的是，以使黑色为染料浓度约9.8％owf、淡茶色为染料浓度约0.25％owf(均是固体成分换算)的方式使用各染料。
另外，在基于dip-nip的防污加工(工序4)中，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％)。
在第一涂覆以及第二涂覆工序中，分别使用以粘度处于45000～55000mPa·s的范围的方式调整出的第一涂覆用组成物或第二涂覆用组成物，并利用刮刀涂布机在布帛的背面形成了涂层。
在第一涂覆以及第二涂覆中使用的阻燃剂(工序10以及工序12)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℃的水的溶解度为4.0％以下)为主要成分的非卤素系阻燃涂覆剂)。
另外，在第一涂覆中使用的氟系疏水疏油剂(工序8以及10)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，在工序8中使用的丙烯酸系树脂是从DIC株式会社以VONCOAT901的名称销售的含丙烯酸系树脂的水分散体，聚氨酯系树脂是从第一工业制药株式会社以superflexE-2000的名称销售的含聚氨酯系树脂的水分散体，聚酯系树脂是从互应化学工业株式会社以PLUS COATZ的名称销售的含聚酯系树脂的水分散体。
另外，在工序8中，使用了从新中村化学工业株式会社以バナゾールKB-660的名称使用的丙烯酸树脂系增稠剂。
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(形成有第一涂层和/或第二涂层的面)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)，之后测定布帛与聚氨酯泡沫的剥离强度、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-VehicleSafetyStandard)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。
＜层压剥离强度>
在层压有聚氨酯泡沫的加工布帛中，从两端部以及中央部沿着纵向以及横向分别各切出三个宽度25mm、长度150mm的尺寸的试验片，在试验片的长边方向的端部，用手预先将布帛与聚氨酯泡沫剥离约50mm。对其以拉拽速度200mm/min进行拉拽，记录剥离载荷。
根据所记录的载荷而从图表求出平均载荷，针对各方向而求出三个部位的平均，算出剥离强度(N/cm)。将剥离强度为1N/cm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将通过dip-nip工序、第一涂覆工序、第二涂覆工序而向基布赋予的各成分的固体成分量表示为布帛的每单位面积的量(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或涂覆面向基布赋予的药剂的固体成分(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(干燥)和WET(湿润)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(仅一层)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。另外，层压剥离强度不充分。
与此相对，在布帛的单面形成有包含氟系疏水疏油剂的第一涂层后，在该第一涂层上形成有包含阻燃剂的第二涂层的情况下(布帛No.5～No.9)，除了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，还在层压品的剥离强度以及阻燃性方面均能够达到所期望的特性。
另外，在染色时不进行浴中阻燃而向第一涂层(防污涂层)添加了阻燃剂的情况下(布帛No.10)，也能够全部达到所期望的特性。然而，由于向第一涂层添加阻燃剂而发现防污性恶化的倾向，因此在向第一涂层添加阻燃剂的情况下，优选以使第一涂层所包含的氟系疏水疏油剂的含量在布帛的每单位面积上为2.5g/m2以上的方式，调整涂覆用组成物的组成和/或涂覆用组成物向布帛涂布的涂布量。
需要说明的是，即使从布帛No.5～No.9的制造工序除去浴中阻燃加工，通过形成包含阻燃剂的第二涂层，布帛单体的阻燃性也能够达到“N”。然而，在作为层压复合体的阻燃性试验的结果中观察到出现波动的倾向，因此在对发泡材料片和层压的布帛不进行浴中阻燃加工的情况下，向第一涂层和第二涂层这两方添加阻燃剂的做法对于达成稳定的阻燃性而言是优选的。
另外，在布帛No.10中，阻燃剂的合计量(第一涂层+第二涂层中的阻燃剂)比布帛No.5～No.9的阻燃剂的量(仅第二涂层中存在阻燃剂)高，但若在布帛No.10中不将阻燃剂分至第一层和第二层而将所述合计量仅添加于第二层，则层压剥离强度因第二涂层变厚而降低。因此，与仅向第二层添加大量的阻燃剂来谋求阻燃性能的提高相比，优选分别向第一层和第二层添加。另外，此时，通过使第二涂层所包含的阻燃剂的量比第一涂层所包含的阻燃剂少，从而能够减薄第二涂层的厚度，实现层压剥离强度的提高，但另一方面，若第一涂层所包含的阻燃剂过多，则色拉油防污性降低。因此，优选以第一层涂层所包含的阻燃剂的量成为25～45g/m2且第二涂层所包含的阻燃剂的量成为15～35g/m2的方式形成各层。
需要说明的是，若在布帛No.10中不进行第二涂覆工序，则与布帛No.4同样，防污性以及层压剥离强度不充分，因此即便在向第一涂层添加了阻燃剂的情况下，第二涂层(包含阻燃剂且不包含疏水疏油剂)也是必需的。
另外，针对No.5～No.10的布帛，若更换第一涂层和第二涂层的顺序而按照布帛、阻燃涂层、防污涂层的顺序层叠，则在布帛的防污试验中产生油渍，而且层压剥离强度变得不充分，因此按照布帛、防污涂层、阻燃涂层的顺序层叠的做法是必需的。
根据以上的实验可知，为了达到所期望的阻燃性、防污性、与发泡材料片的剥离强度等，在含浸有氟系疏水疏油剂的布帛的单面(尤其是背面)上，将包含氟系疏水疏油剂的第一涂层、包含阻燃剂的第二涂层按照布帛、第一涂层、第二涂层的顺序设置的做法是有效的。
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，因此适合用作机动车等交通工具的内部装饰用布帛。

Claims (9)

1.一种布帛，其特征在于，
在含浸有氟系疏水疏油剂的聚酯系布帛的一方的面具有第一涂层和第二涂层，
所述第一涂层是包含氟系疏水疏油剂的层，所述第二涂层是包含阻燃剂的层，
布帛的一侧为第一涂层，第一涂层中的与布帛相反的一侧为第二涂层。
2.根据权利要求1所述的布帛，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，其中，
在所述布帛的所述一方的面上还紧贴固定有发泡材料片。
4.根据权利要求1至3中任一项所述的布帛，其中，
所述第一涂层所包含的氟系疏水疏油剂在布帛的每单位面积上的含量为0.5g/m2～5.0g/m2。
5.根据权利要求1至4中任一项所述的布帛，其中，
所述第一涂层还包含阻燃剂。
6.根据权利要求1至5中任一项所述的布帛，其中，
所述第一涂层所包含的氟系疏水疏油剂以及阻燃剂在布帛的每单位面积上的含量分别为0.5g/m2～3.0g/m2以及0g/m2，
所述第二涂层所包含的阻燃剂在布帛的每单位面积上的含量为30g/m2～60g/m2。
7.根据权利要求1至5中任一项所述的布帛，其中，
所述第一涂层所包含的氟系疏水疏油剂以及阻燃剂在布帛的每单位面积上的含量分别为2.5g/m2～5.0g/m2以及25g/m2～45g/m2，
所述第二涂层所包含的阻燃剂在布帛的每单位面积上的含量为15g/m2～35g/m2，
第一涂层所包含的阻燃剂的含量比第二涂层所包含的阻燃剂的含量多。
8.根据权利要求1至7中任一项所述的布帛，其中，
所述布帛具备阻燃性以及防污性。
9.一种布帛的制造方法，其中，
所述布帛的制造方法包括如下工序：
在将聚酯系布帛浸渍于包含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；
在所述布帛的一方的面上形成包含氟系疏水疏油剂的第一涂层；以及
在所述第一涂层之上形成包含阻燃剂的第二涂层。
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