CN1933750A - 层状高膨松性耐火棉胎、含所述棉胎的制品及其制备方法 - Google Patents
层状高膨松性耐火棉胎、含所述棉胎的制品及其制备方法 Download PDFInfo
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- CN1933750A CN1933750A CNA2005800090204A CN200580009020A CN1933750A CN 1933750 A CN1933750 A CN 1933750A CN A2005800090204 A CNA2005800090204 A CN A2005800090204A CN 200580009020 A CN200580009020 A CN 200580009020A CN 1933750 A CN1933750 A CN 1933750A
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Classifications
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Abstract
本发明涉及高膨松性防火棉胎，和含有所述棉胎的制品比如床垫；所述棉胎包括基层和弹性层，所述基层含有10－30重量份耐热纤维、35－55重量份纤维素纤维、和15－25重量份粘合剂材料，其中所述纤维素纤维当在空气中以每分钟20℃的速率加热到700℃时至少保留其纤维重量的10％；所述弹性层含有0－50重量％改良丙烯酸纤维、50－85重量份数的聚酯纤维、和15－25重量份的粘合剂材料。基于基层和弹性层的总重量，该基层占棉胎的20－70重量份，弹性层占棉胎的80－30重量份，棉胎的总厚度是1.25厘米(0.5英寸)或更大。
Description
背景技术
1、技术领域
本发明涉及用于制品比如床垫防火的层状高膨松性耐火棉胎以及制备所述棉胎的方法和制品防火的方法。采用了本发明的高膨松性防火棉胎的床垫套装在燃烧时，根据2003年7月修订的Technical Bulletin603 of the State of California进行测试，在30分钟内峰值放热速率小于200千瓦，在10分钟内总放热量小于25兆焦耳。
2、相关技术描述
为了设法减少在住宅、旅馆和公共设施火灾中丧生的人数，加利福利亚州已经开始控制和降低床垫和床垫套装的可燃性。具体而言，加利福利亚州的Bureau of Home Furnishings and Thermal Insulationof the Department of Consumer Affairs发布了Technical Bulletin 603“Requirements and Test Procedure for Resistance of a ResidentialMattress/Box Spring Set to a Large Open-Flame”，以对床垫套装的可燃性性能进行量化。
正常情况下，床垫含有床垫芯，床垫芯上覆盖着缓冲材料或者棉胎，缓冲材料或棉胎进而又覆盖有外层织物套。大多数缓冲材料或者棉胎由当暴露于明火中时将会燃烧的泡沫或者纤维材料制成。在Blaustein等的美国专利No.4750443中公开了一种可用于泡沫缓冲垫尤其是飞机座椅防火的方法，其中在座椅的罩层织物下采用了三至七层防火织物将泡沫封装起来。为了达到飞机座椅可燃性测试方法所需的程度，这些防火缓冲垫经受喷到其上的喷射火焰，防止整个缓冲垫被火焰吞噬或者在移开喷射火焰后继续燃烧。当应用到床垫中时，在套子下面采用多个防火层可能使刚性增加或者限制床垫芯的弹性，从而影响整体的舒适度。即使单层防火织物也可能使棉胎材料受到限制和影响床垫的缓冲性。所以，需要的是不需要结合另外的防火层的解决方案。具体而言，需要的是也可以作为床垫或者带有装饰物的制品的防火物的棉胎材料。
纤维，比如对芳族聚酰胺是非常有用的防火织物，但是这些纤维有天然的金色，这种颜色在由大量这些纤维制成的织物中会显示出来。对芳族聚酰胺的天然金色透过正常情况下为白色或者浅色或者灰白色的床垫外套显示出来，或者透过家具的外面装饰性罩层织物显示出来，都是不理想的。所以，需要的是高膨松性防火棉胎，该棉胎结合有耐热纤维，其中耐热纤维的颜色被该高膨松性防火床垫的其它纤维掩盖，同时仍然满足重要的防火性要求。
PCT公开WO 03/023108公开了用于床垫和带有装饰物的家具的非织造型高膨松性防火物。这些防火物密度非常低，每立方米为5-50千克，最优选每立方米7.5千克。优选的非织造型高膨松性防火物包括纤维混合物，该纤维混合物包括具有固有防火性并能抵抗由于直接火焰导致收缩的纤维，和用卤化单体制成的聚合物制成的纤维。
美国专利No.6132476、6547835和5609950公开了具有固有防火性的纤维和耐火性提高的纤维素纤维的织物混合物；该织物可以包含另外加入的防火物，例如，以染色步骤中的添加剂形式。由于无机材料的含量低，所以在这些参考文献中公开的防火性纤维素纤维当暴露到高温下时，不能保留其重量的足量百分比。
美国专利No.6579396和6383623公开了由非热塑性纤维和热塑性粘合剂材料制成的、密度为0.1-3.0磅/立方英尺的高温绝热材料。粘合剂材料完全熔融，液化的热塑性材料假设在表面张力的作用下集中到非热塑性纤维汇集的位点处，在冷却时形成结点，这和套-芯式粘合剂纤维不同，后者可以将许多纤维沿着粘合剂纤维的长度方向结合到粘合剂纤维上，并在加热后保留热塑性材料芯。
美国专利No.4199642公开了80-98％的聚酯纤维填料和2-20％合成有机丝状材料的紧密混合物。所述有机丝状材料可以是聚(对亚苯基对苯二酰胺)或者防火性人造丝。
美国专利No.5578368公开了防火性材料，含有纤维填料毛层和至少一个芳族聚酰胺纤维防火层。
发明内容
本发明涉及高膨松性防火棉胎和含有所述棉胎的制品，比如床垫；该棉胎包括基层和弹性层，基层含有10-30重量份耐热纤维、35-55重量份纤维素纤维、和15-25重量份粘合剂材料，其中所述纤维素纤维当在空气中以每分钟20℃的速率加热到700℃时至少保留其纤维重量的10％；所述弹性层含有0-50重量份改良丙烯酸纤维、50-85重量份的聚酯纤维、和15-25重量份的粘合剂材料。基于基层和弹性层的总重量，该基层占棉胎的20-70重量份，弹性层占棉胎的80-30重量份，棉胎的总厚度是1.25厘米(0.5英寸)或更大。
本发明还涉及制备高膨松性防火棉胎的方法，包括下列步骤：
a)形成基层纤维混合物，包括10-30重量份耐火纤维、35-55重量份纤维素纤维、和15-25重量份粘合剂纤维，其中所述纤维素纤维当在空气中以每分钟20℃的速率加热到700℃时至少保留其纤维重量的10％；
b)形成弹性层纤维混合物，包括0-50重量份改良丙烯酸纤维、50-85重量份的聚酯纤维、和15-25重量份的粘合剂纤维；
c)形成总厚度为至少1.25厘米(0.5英寸)的层状毛层，其中一层含有所述基层纤维混合物，另一层含有所述弹性层纤维混合物；和
d)加热所述层状毛层，以使粘合剂纤维活化和形成高膨松性棉胎。
任选地，可以将高膨松性棉胎的一部分循环利用到基层纤维混合物中。
本发明进一步涉及结合有层状高膨松性防火棉胎的防火被褥以及制品防火的方法，包括下列步骤：
a)将织物褥罩或者装饰物层、高膨松性棉胎、以及任选的缝合衬里层组合在一起，所述高膨松性棉胎包括
包括10-30重量份耐热纤维、35-55重量份纤维素纤维和15-25重量份粘合剂材料的基层，所述纤维素纤维当在空气中以每分钟20℃的速率加热到700℃时至少保留其纤维重量的10％；和
含有0-50重量份改良丙烯酸纤维、50-85重量份聚酯纤维、和15-25重量份粘合剂材料的弹性层；
基于基层和弹性层的总重量，该基层占棉胎的20-70重量份，弹性层占棉胎的80-30重量份，棉胎的总厚度至少是1.25厘米(0.5英寸)，
b)将所述层缝制在一起，形成防火被褥或者装饰织物，和
c)将防火被褥或者装饰织物结合到制品中。
具体实施方式
本发明涉及层状高膨松性防火棉胎以及含所述棉胎的制品，比如床垫。棉胎包括一起作用以形成防火材料的基层和弹性层。基层包括10-30重量份耐热纤维、35-55重量份纤维素纤维和15-25重量份粘合剂材料，其中所述纤维素纤维当在空气中以每分钟20℃的速率加热到700℃时至少保留其纤维重量的10％；弹性层包括0-50重量份改良丙烯酸纤维、50-85重量份的聚酯纤维、和15-25重量份的粘合剂材料。在所述层状高膨松性棉胎中，基于基层和弹性层的总重量，基层的含量是20-70重量份，弹性层的含量是80-30重量份。
本发明的高膨松性棉胎的总厚度是1.25厘米(0.5英寸)或以上。尽管对棉胎的可能厚度并没有真正的限制，但是对于许多典型应用而言，所述高膨松性棉胎的厚度无需大于7.6cm(3英寸)，而且对于许多床垫应用而言小于5cm(2英寸)是极其有用的。本发明的层状棉胎优选的基础重量为每平方码8-12盎司。基于组合层的总重量和厚度，棉胎也具有5.3-32千克每立方米(0.33-2.0磅每立方英尺)的优选复合密度。一般而言，更致密的棉胎并不具有对于在床垫和其它制品中用作缓冲层而言所需的弹性。不认为比所需范围薄或者致密性差的棉胎会提供所需的缓冲量。
层状高膨松性棉胎的基层含有10-30重量份的耐热纤维、35-55重量份纤维素纤维和15-25重量份粘合剂材料，其中所述纤维素纤维当在空气中以每分钟20℃的速率加热到700℃时至少保留其纤维重量的10％。优选地，耐热纤维的含量是20-30重量份，纤维素纤维的含量是40-50重量份。基层提供了在火焰中形成炭并维持完整性的致密结构。
“耐热纤维”是指当以每分钟20℃的速率在空气中加热到500℃时优选保留其90％纤维重量的纤维。这种纤维正常情况下具有防火性，是指由具有如下极限氧指数(LOI)的纤维制备的纤维或织物：所述极限氧指数使得所述纤维或织物在空气中不能为火焰提供支持，优选的LOI范围是大约26或以上。优选的纤维当暴露于火焰中时，不会过分收缩，也即，当暴露于火焰中时纤维长度并不明显缩短。含有当在空气中以每分钟20℃的速率加热到500℃时保留90％纤维重量的有机纤维的织物，当被扑面而来的火焰燃烧时，往往出现有限量的裂纹和开口，这对于织物作为防火物的性能而言很重要。
可用于本发明的非织造型防火织物的耐热稳定纤维包括由对芳族聚酰胺、聚吲哚、聚苯并咪唑和聚酰亚胺聚合物制备的纤维。优选的耐热纤维是由芳族聚酰胺聚合物，尤其是对芳族聚酰胺聚合物制备的耐热纤维。
本文使用的“芳族聚酰胺”是指其中至少85％的酰胺(-CONH-)键直接连接到两个芳环上的聚酰胺。“对芳族聚酰胺”是指两个环或者基团沿着分子链互相对位取向。可以和芳族聚酰胺一起使用添加剂。实际上，发现多达10重量％的其它聚合物材料可以和芳族聚酰胺混合，或者可以采用用多达10重量％的其它二胺取代芳族聚酰胺中的二胺的共聚物或者用多达10重量％的其它二酰基氯取代芳族聚酰胺中的二酰基氯的共聚物。在本发明的实践中，优选的对芳族聚酰胺是聚(对亚苯基对苯二酰胺)。在例如美国专利No.3869430、3869429和3767756中，一般性地公开了可用于本发明的对芳族聚酰胺的制备方法。这些芳族聚酰胺有机纤维和这些纤维的各种形式可得自DupontCompany，Wilmington，Delware，商标为Kevlar纤维。
可用于本发明的商业可得的聚吲哚包括可得自Toyobo，Japan的ZylonPBO-AS(聚(对亚苯基-2，6-苯并二唑)纤维、ZylonPBO-HM(聚(对亚苯基-2，6-苯并二唑))纤维。可用于本发明的商业可得的聚苯并咪唑纤维包括可得自Celanese Acetate LLC的PBI纤维。可用于本发明的商业可得的聚酰亚胺纤维包括可得自LaPlaceChemical的P-84纤维。
层状高膨松性棉胎的基层还包括35-55重量份的纤维素纤维，该纤维素纤维当在空气中以每分钟20℃的速率加热到700℃时保留至少10％的其纤维重量。这些纤维被称为成炭纤维。用于本发明复合物的纤维素纤维优选是纤维中结合了10重量％无机化合物的再生纤维素纤维。这种纤维和其制备方法一般性地公开在美国专利No.3565749和英国专利No.1064271中。对本发明而言，优选的成炭再生纤维素纤维是含有二氧化硅的粘胶纤维，所述二氧化硅是具有硅酸铝位点的聚硅酸形式。这种纤维和其制备方法一般性地公开在美国专利No.5417752和PCT专利申请WO9217629中。含有硅酸并具有大约31(+/-3)％无机材料的粘胶纤维由Sateri Oy Company of Finland销售，商标名为Visil。
层状高膨松性棉胎的夹层还含有15-25重量份的粘合剂材料。优选的粘合剂材料是通过施加热量而活化的粘合剂纤维。这些粘合剂纤维通常由在比纤维掺合物中任何其它切段纤维的软化点低的温度下流动(即，具有更低的软化点)的热塑性材料制备。套/芯式双组分纤维作为粘合剂纤维而言是优选的，尤其是如下的双组分粘合剂纤维：具有聚酯均聚物的芯和共聚酯的套，所述共聚酯是粘合剂材料，比如通常可得自Unitika Co.，Japan的那些(例如，商标名为MELTY)。有用的粘合剂纤维类型可以包括由聚丙烯、聚乙烯、或者聚酯聚合物或共聚物制备的那些，仅仅含有所述聚合物或者共聚物的纤维，或者是具有并排构造或者套/芯构造的双组分纤维。
层状高膨松性棉胎的弹性层含有0-50重量份的改良丙烯酸纤维、50-85重量份的聚酯纤维、和15-25重量份的粘合剂材料。弹性层优选用作层状高弹性棉胎的外层，提供了在火焰中牺牲性地熔化并任选放出气体来抑制火焰的弹性结构。弹性层通常是白色或者浅色，还优选地屏蔽基层的任何着色。
弹性层含有50-85重量份的聚酯纤维，以为层状棉胎提供弹性。如果采用的多于85重量份的聚酯纤维，相信棉胎会变得过分易燃而不能用于防火物中。聚酯纤维是本领域公知的，可以从许多来源获取。优选的聚酯纤维由聚(对苯二甲酸乙二酯)(PET)聚合物制成。但是，可以采用其它的聚酯，比如聚酯聚合物与聚(对苯二甲酸丙二酯)、聚(对苯二甲酸丁二酯)、聚(1，4-环亚己基-二亚甲基对苯二甲酸酯)的单体和其共聚物和混合物的均聚物、共聚物、三聚物和掺合物等。可用于本发明的一种类型的PET纤维可得自Invista，Inc.OfWilmington，Delaware，商标名为DACRONType 808单空中空纤维，线密度为7.2分特/丝(6.5旦尼尔/丝)，切断长度为3.8cm(1.5英寸)。
弹性层还含有15-25重量份粘合剂材料。和在基层中一样，优选的粘合剂材料是通过施加热量活化的粘合剂纤维。一般而言，同样的粘合剂可用于弹性层和基层中。但是，并不要求如此。
弹性层任选地还含有0-50重量份的改良丙烯酸纤维。由于改良丙烯酸纤维在燃烧时释放出抑制火焰的含卤气体，所以可用于棉胎的外层。改良丙烯酸纤维是指由包括丙烯腈的聚合物制成的丙烯酸合成纤维。优选地，聚合物是含有30-70重量％的丙烯腈和70-30重量％的含卤素的乙烯基单体的共聚物。含卤素的乙烯基单体是选自例如氯乙烯、偏氯乙烯、溴乙烯、偏溴乙烯等的至少一种单体。可共聚的乙烯基单体的例子是丙烯酸、甲基丙烯酸、所述酸的盐或酯、丙烯酰胺、甲基丙烯酰胺、和乙酸乙烯酯等。
用于本发明的优选改良丙烯酸纤维是丙烯腈和偏氨乙烯的共聚物，该共聚物另外具有一种或多种锑氧化物以改善阻燃性。这种有用的改良丙烯酸纤维包括但不限于在美国专利No.3193602中公开的具有2重量％三氧化锑的纤维、在美国专利No.3748302中公开的具有含量至少为2重量％并优选不大于8重量％的各种锑氧化物的纤维、和在美国专利No.5208105和5506042中公开的具有8-40重量％的锑化合物的纤维。优选的改良丙烯酸纤维是可得自Kaneka Corporation，Japan的Protex C，据称该纤维含有10-15重量的锑氧化物，但是也可以采用具有更少锑氧化物(6重量％或以下)的纤维。
在层状高膨松性棉胎中，基于基层和弹性层的总重量，基层的含量是20-70重量份，弹性层的含量是80-30重量份。优选的，基层含量为40-55重量份，弹性层含量为60-45重量份。
本发明还涉及制备高膨松性防火棉胎的方法，包括下列步骤：
a)形成基层纤维混合物，该混合物包括10-30重量份耐热纤维、35-55重量份纤维素纤维和15-25重量份粘合剂材料，所述纤维素纤维当在空气中以每分钟20℃的速率加热到700℃时至少保留其纤维重量的10％；
b)形成弹性层纤维混合物，该混合物包括0-50重量份改良丙烯酸纤维、50-85重量份聚酯纤维和15-25重量份粘合剂材料的弹性层；
c)形成总厚度至少为1.25厘米(0.5英寸)的层状毛层，其中一层含有基层纤维混合物，另一侧含有弹性层纤维混合物；和
d)加热所述层状毛层，以激活粘合剂纤维并形成高膨松性棉胎。
纤维混合物和层状毛层可以由能够形成低密度网幅的任何方法形成。例如，从大捆纤维中获取的卷曲的切段纤维和粘合剂纤维的簇，可以用设备比如清棉机打开。优选的，这些纤维是线密度为大约0.55-大约110分特每丝(0.5-100旦尼尔每丝)、优选0.88-56分特/丝(0.8-50旦尼尔/丝)、最优选约1-33分特/丝(0.9-30旦尼尔/丝)的切段纤维。一般而言，该纤维的切断长度为大约1.3cm-10.2cm(0.5-4英寸)，优选的卷曲频率为大约2.4-5.9卷每厘米(6-大约15卷/英寸)。
打开的纤维混合物随后可以通过任何可得的方法比如空气输送掺混以形成更加均匀的混合物。可替换地，可以在在清棉机中打开纤维之前将纤维掺混以形成均匀的混合物。随后，可以将纤维的掺混物通过设备比如梳理机转化为纤维网幅，但是可以采用其它方法，比如纤维的气流成网法。随后，可以将纤维网幅经由传输机送到设备比如交叉铺网机中，通过将单个网幅按照锯齿结构一个接一个的铺层，从而形成高膨松性的交叉铺网结构。控制纤维打开和交叉铺网的速率，以产生所需高度的高膨松性交叉铺网结构。可用于获得交叉铺网结构的代表性方法，包括用于在带上或者皮圈上交叉铺网通过气流成网或者其它方式形成的网幅的方法，是本领域公知的，一般性地公开在Manns的美国专利3558029、Asselin等的3877628、Freund的4984772、Jourde等的6195844、和Jowett的英国专利1527230中。
为了创建本发明的多层高膨松性棉胎，可以制备两个或多个高膨松性的、具有不同组成、优选是上述基层和弹性层的组合物的结构，所述结构可以同时或者顺序制备，然后一个接一个地堆叠在传输机或带上。随后，通过施加热量，优选通过采用加热烘箱，来激活粘合剂材料，以使该层状高膨松性网幅棉胎固化，优选不压缩棉胎。随后，高膨松性棉胎冷却以使粘合剂材料固化。
在优选方法中，层状高膨松性棉胎的边缘随后经过修剪以提供宽度均匀的棉胎。高膨松性棉胎被修剪的部分随后循环回到方法中，优选通过清棉机对该材料进行处理，该清棉机将修剪的边缘分隔成单个的纤维。该循环利用的部分含有来自基层和弹性层两者的纤维，所以为了维持弹性层的颜色一致性，优选将该循环利用部分加到基层中。但是，由于基层为层状棉胎提供在火焰中的完整性，而该循环利用的材料含有可燃性的纤维，所以循环利用的材料在基层中的加入量必须限制。优选地，循环到基片中的总量小于基片总重量的大约25重量％。优选地，通过该循环利用方法，基层可以另外地含有占基层多达15重量份的聚酯纤维和占基层多达5重量份的改良丙烯酸纤维。
本发明还包括含有本文所述层状高膨松性棉胎的防火制品。优选地，该制品是含有被褥嵌料(quilt panel)的床垫，所述被褥嵌料结合有本发明的高膨松性网幅棉胎。床垫被褥嵌料可以通过将褥罩织物层、一层或多层本发明的层状高膨松性棉胎、任选的泡沫、以及需要时的纱布衬里(scrim backing)组合在一起制备，其中所述纱布衬里用在床垫被褥的面向床垫内部的一侧上。
褥罩织物正常情况下是采用了任何数量织纹(weave)的耐久性极强的织造或者编织织物，往往基础重量为2-8盎司每平方码(68-271克每平方米)。通常的褥罩织物可以含有但不限于棉花、聚酯纤维或者人造丝纤维。泡沫通常是聚氨酯泡沫。纱布衬里通常是0.5-1盎司/平方码的非织造(一般是纺粘的)织物。床垫被褥嵌料的层可以通过用线缝合的缝线牢固地结合在一起。
本发明的层状高膨松性棉胎可以作为防火层结合到床垫、底座、和/或弹簧床垫中。例如，床垫、底座和/或弹簧床垫的嵌料和滚边可以采用前述的床垫被褥嵌料或者结合了本发明的层状高膨松性棉胎作为部件的其它变体。可以用非防火性的线进行缝合，但是，对于缝合尤其是缝合床垫、底座和/或弹簧床垫的滚边而言，优选防火性的线，比如Kevlar芳族聚酰胺纤维制成的线。
本发明进一步涉及制品防火的方法，包括下列步骤：
a)将织物褥罩或者装饰物、高膨松性棉胎、和任选的缝合衬里(stitch backing)层组合在一起，所述高膨松性棉胎包括基层和弹性层，所述基层包括10-30重量份耐热纤维、35-55重量份纤维素纤维和15-25重量份粘合剂材料，所述纤维素纤维当在空气中以每分钟20℃的速率加热到700℃时至少保留其纤维重量的10％；所述弹性层包括0-50重量份改良丙烯酸纤维、50-85重量份聚酯纤维和15-25重量份粘合剂材料的弹性层；基于所述基层和弹性层的总重量，所述基层占棉胎的20-70重量份，所述弹性层占棉胎的80-30重量份，所述棉胎的总厚度为至少1.25厘米(0.5英寸)，
b)将所述层缝制在一起，以形成防火被褥或者装饰性织物，和
c)将所述防火被褥或者装饰性织物结合到制品中。
测试方法
热重分析。用于本发明的纤维当以特定加热速率加热到高温时保留部分的纤维重量。该纤维重量采用得自TA Instruments(WatersCorporation的分公司)，Newark，Delware的Model 2950热重分析仪进行测量。TGA给出温度升高和试样重量损失的关系曲线。采用TAUniversal Analysis程序，可以在任何记录的温度测量重量百分比损失。程序方案由以下构成：将试样在50℃平衡；以10-20℃/分从50℃升温到1000℃；采用空气作为气体，以10ml/分钟供应；和采用500微升的陶瓷杯状(PN952018.910)试样容器。
测试程序如下。采用TGA屏幕在TA Systems 2900控制器上对TGA进行编程。输入试样ID，选择计划好的20℃/分的升温程序。利用该仪器的皮重功能对该空试样杯进行皮重处理。将纤维试样切成大约1/16”(0.16cm)长度，用该试样松散填充试样盘。试样重量应该为10-50mg。TGA具有秤，所以无需预先确定精确重量。不应有试样落在盘的外面。将填充的试样盘加载到秤丝(balance wire)上，确保热电偶靠近该盘的顶边但不接触。将炉子上升到该盘的上方，启动TGA。一旦程序完成，TGA将自动使炉子下降、取出试样盘、并进入冷却模式。随后，采用TA Systems 2900 Universal Analysis程序分析和生成在温度范围内的重量损失百分比曲线。
厚度。可以采用ASTM D5736-95(2001年的再次通过版本)测量层状棉胎的厚度。
床垫燃烧性能。Bureau of Home Furnishings and ThermalInsulation of the Department of Consumer Affairs of the State ofCalifornia(3485 Orange Grove Avenue，North Highlands，California95660-5595，USA)公布了Technical Bulletin 603“Requirements andTest Procedure for Resistance of a Residential Mattress/Box Spring Setto a Large Open-Flame”，载明的日期为2003年2月，用以定量化床垫套装的易燃性性能。该公布随后在2003年7月进行了修订，要求峰值放热速率(PHRR)的极限值小于200千瓦，10分钟的总放热极限值小于25兆焦耳。该协议提供了确定床垫/底座燃烧行为的方法，即通过将床垫和底座在通风良好的条件下暴露到特定的点火源时测量特定的燃烧测试响应。该协议基于载明日期为2003年2月的NationalInstitute of Standards and Technology Publication的标题为“Protocol ofTesting Mattress/Foundation Sets Using a Pair of Gas Burners”。
获得了描述下列燃烧的测试数据：在施加特定的煤气燃烧器对的过程期间和之后，从点火点直到(1)该睡觉套装的燃烧完全终止，(2)过去了30分钟，或者(3)测试屋中不可避免地出现飞弧。通过氧消耗量热法测量了从正在燃烧的测试试件释放热量(燃烧产生的能量)的速率。在ASTM E 1590“Standard Test Method of Fire Testing ofMattresses”中有对原理、限制和必要测试仪器的讨论。在ASTM E 176“Standard Terminology of Fire Standards”中定义了和该测试相关的术语。
一般而言，测试协议采用了一对丙烷燃烧器，该丙烷燃烧器经设计来模仿通过燃烧床布在床垫和底座上施加的热流量水平和持续时间。燃烧器在床垫顶部和床垫/底座侧面施加不同时间的不同流量。在该暴露期间和之后，测量从测试试件散热的时间相关性速率。
将床垫/底座置于短床架的顶部，该床架设置在制动表面上(catchsurface)。在测试期间，由用以测量放热速率的捕捉器捕获烟缕。从实用性考虑，测量了双人(twin-sized)床垫和底座。在由燃烧器点火后，让试样在良好通风的条件下自由燃烧。
测试试件包括放置在底座上的床垫，该底座具有T型燃烧器组来燃烧试件。一个燃烧器将火焰对准床垫的顶表面，设置成距离床垫的所述表面39mm。第二燃烧器将火焰垂直对准床垫/底座组合的侧面，设置成距离试件的所述侧面42mm。侧燃烧器和顶燃烧器并没有在沿着试件长度方向上设置在相同的位置，而是在沿着长度上相距大约18-20cm。针对该测试方法特别构造了该燃烧器并进行了校准。
测试试件在测试前，在高于12℃(54)的环境温度和小于70％的相对湿度下调制24小时。床垫和底座的测试试件互相对中，并在床架和制动表面居中。如果床垫比底座窄1-2cm，则床垫可以移动直到床垫和底座的侧面垂直对齐为止。按照标准将燃烧器校准并和试件间隔一定距离。在点火之前的至少一分钟时，打开数据记录和检测设备。燃烧器点火，让顶燃烧器燃烧70秒，而让侧燃烧器燃烧50秒(如果可行)，然后将燃烧器从该区域中移开。持续收集数据，直到所有的燃烧和阴烧信号都停止为止或者过了一小时为止。
实施例
制备具有基层和弹性层的两层高膨松性棉胎，采用熔融温度为120℃的、共聚物PET套/PET芯粘合剂纤维将两层中的纤维固定就位。采用常规梳理生产线(carding lines)/扯松机和交叉铺网机打开和掺混纤维，形成各个高膨松性棉胎层，将这些层组合在一起并采用燃气烘箱热固化。随后，使高膨松性棉胎冷却。一部分该高膨松性棉胎循环回到梳理机中，来自该循环部分的纤维成为基层的一部分。基层除了该循环材料以外，含有单丝旦尼尔为2.2dpf、平均切断长度为2英寸的型号为970Kevlar的芳族聚酰胺纤维(得自DuPont)、单丝旦尼尔为3.5dpf、平均切断长度为50mm的型号为33AP Visil纤维素纤维(得自Sateri)、和单丝旦尼尔为4dpf、平均切断长度为51mm的粘合剂纤维(得自Nan Ya)。弹性层具有单丝旦尼尔为15dpf、平均切断长度为64mm的PET聚酯纤维(得自KG)、单丝旦尼尔为7dpf、平均切断长度为51mm的Protex C改良丙烯酸纤维(得自Kaneka)以及和基层相同的粘合剂纤维。
下表中给出了测试项、纤维掺混重量比、基层和顶层的基础重量。这些项的厚度为大约2.5-3.8cm(1-1.5英寸)。
表
| 基层 | 顶层 | ||||||||
| 项 | BW | Kevlar | Visil | 粘合剂 | 循环 | BW | 改良丙烯酯 | PET | 粘合剂 |
| 1 | 5osy | 30 | 50 | 20 | 5osy | 50 | 30 | 20 | |
| 2 | 5osy | 30 | 50 | 20 | 7osy | 50 | 30 | 20 | |
| 3 | 5osy | 20 | 40 | 20 | 20 | 5osy | 20 | 60 | 20 |
| 4 | 4osy | 20 | 40 | 20 | 20 | 5osy | 20 | 60 | 20 |
| 5 | 4osy | 20 | 40 | 20 | 20 | 5osy | 0 | 80 | 20 |
循环部分的组成：20％粘合剂、15％Kevlar、25％Visil、25％的改良丙烯酸、15％PET
随后，对该高膨松性棉胎在单面和双面床垫中的明火测试协议TB603进行测试。
制备四个单面床垫进行测试。两个床垫在顶部嵌料上的褥罩下方结合了第1项，两个床垫在顶部嵌料上的褥罩下方结合了第3项。所有四个床垫的床垫滚边都采用了包括两个射流喷网织物层作为防火物的织物；一个射流喷网层的基础重量为2.5盎司/平方码，包括Kevlar芳族聚酰胺纤维和Visil纤维素纤维的50/50％混合物。另一射流喷网层的基础重量为4.0盎司/平方码，包括Visil纤维和Protex C改良丙烯酸纤维的33％/67％混合物。在底座的滚边中采用了相同的防火物。在底座嵌料上采用的防火物是单层射流喷网层，该喷网层的基础重量为4.0盎司/平方码，包括Kevlar芳族聚酰胺纤维和Visil纤维素纤维的25％/75％混合物。
同样制备了四个双面床垫进行测试。它们的制备和单面床垫相同，不同之处在于在两个床垫中结合了第1项，两个床垫中结合了第4项，并且由于这些床垫是双面床垫，所以在床垫的两个嵌料中都结合了所述高膨松性层状棉胎。所有其它材料都相同。
在测试时，所有床垫在30分钟内的峰值放热速率小于200千瓦，在10分钟内的总放热量小于25兆焦耳，所述测试根据的是2003年7月修订的Technical Bulletin 603 of the State of California。
Claims (25)
1、高膨松性防火棉胎，包括：
(a)基层，包括
(i)10-30重量份耐热纤维，
(ii)35-55重量份纤维素纤维，所述纤维素纤维当在空气中以每分钟20℃的速率加热到700℃时至少保留其纤维重量的10％，和
(iii)15-25重量份粘合剂材料；
(b)弹性层，包括
(i)0-50重量份改良丙烯酸纤维，
(ii)50-85重量份聚酯纤维，和
(iii)15-25重量份粘合剂材料；
基于基层和弹性层的总重量，该基层占棉胎的20-70重量份，弹性层占棉胎的80-30重量份，棉胎的总厚度是1.25厘米(0.5英寸)或以上。
2、权利要求1的高膨松性防火棉胎，其中所述耐热纤维是当在空气中以每分钟20℃的速率加热到500℃时保留其纤维重量的90％的有机纤维。
3、权利要求2的高膨松性防火棉胎，其中所述耐热纤维包含对芳族聚酰胺、聚吲哚、聚苯并咪唑或者聚酰亚胺聚合物。
4、权利要求3的高膨松性防火棉胎，其中所述对芳族聚酰胺是聚(对亚苯基对苯二甲酸酰胺)。
5、权利要求1的高膨松性防火棉胎，其中所述纤维素纤维是含有硅酸的粘胶纤维。
6、权利要求1的高膨松性防火棉胎，其总复合密度为0.33-2.0磅每立方英尺。
7、权利要求1的高膨松性防火棉胎，基础重量为8-12盎司每平方码。
8、权利要求1的高膨松性防火棉胎，其中在弹性层中改良丙烯酸纤维的含量为20-50重量份。
9、权利要求1的高膨松性防火棉胎，其中在弹性层中聚酯纤维的含量为30-60重量份。
10、权利要求1的高膨松性防火棉胎，其中在基层中耐热纤维的含量为20-30重量份。
11、权利要求1的高膨松性防火棉胎，其中在基层中纤维素纤维的含量为40-50重量份。
12、权利要求1的高膨松性防火棉胎，其中所述基层进一步含有多达15重量份的聚酯纤维。
13、权利要求1的高膨松性防火棉胎，其中所述基层进一步含有多达5重量份的改良丙烯酸纤维。
14、权利要求1的高膨松性防火棉胎，其中所述粘合剂材料是粘合剂纤维。
15、一种制品，含有权利要求1的高膨松性耐火棉胎作为防火层。
16、一种床垫，含有权利要求1的高膨松性耐火棉胎作为防火层。
17、制备高膨松性耐火棉胎的方法，包括下列步骤：
(a)形成基层纤维混合物，该纤维混合物包含
(i)10-30重量份耐热纤维，
(ii)35-55重量份纤维素纤维，所述纤维素纤维当在空气中以每分钟20℃的速率加热到700℃时至少保留其纤维重量的10％，和
(iii)15-25重量份粘合剂材料；
(b)形成弹性层纤维混合物，该纤维混合物包含
(i)0-50重量份改良丙烯酸纤维，
(ii)50-85重量份聚酯纤维，和
(iii)15-25重量份粘合剂材料；
c)形成总厚度至少1.25厘米(0.5英寸)的层状毛层，其中一层含有所述基层纤维混合物，另一层含有所述弹性层纤维混合物；和
d)加热所述层状毛层以激活粘合剂纤维和形成高膨松性棉胎。
18、权利要求17的方法，其中所述基层纤维混合物在层状毛层中的含量是占所述高膨松性棉胎总重量的20-70重量份。
19、权利要求17的方法，其中所述弹性层纤维混合物在层状毛层中的含量是占所述高膨松性棉胎总重量的80-30重量份。
20、权利要求17的方法，其中所述层状毛层通过首先形成基层纤维混合物和弹性层纤维混合物的独立网幅并随后将所述网幅互相铺层而形成。
21、权利要求17的方法，包括另外的步骤：
a)使一部分所述高膨松性棉胎循环，其中所述循环部分的纤维变成基层纤维混合物的一部分。
22、权利要求21的方法，其中所述循环的纤维不多于基层纤维混合物重量的25重量份。
23、防火被褥，包括外层织物褥罩或者织物罩层、一层或多层层状高膨松性防火棉胎、和任选的缝合衬里层；
其中所述高膨松性棉胎包括
(a)基层，包括
(i)10-30重量份耐热纤维，
(ii)35-55重量份纤维素纤维，所述纤维素纤维当在空气中以每分钟20℃的速率加热到700℃时至少保留其纤维重量的10％，和
(iii)15-25重量份粘合剂材料；
(b)弹性层，包括
(i)0-50重量份改良丙烯酸纤维，
(ii)50-85重量份聚酯纤维，和
(iii)15-25重量份粘合剂材料；
基于基层和弹性层的总重量，该基层占棉胎的20-70重量份，弹性层占棉胎的80-30重量份，棉胎的总厚度是1.25厘米(0.5英寸)或以上。
24、制品防火的方法，包括下列步骤：
a)将织物褥罩或者装饰物层、高膨松性棉胎、以及任选的缝合衬里层组合在一起，所述高膨松性棉胎包括
基层，所述基层包括
(i)10-30重量份耐热纤维，
(ii)35-55重量份纤维素纤维，所述纤维素纤维当在空气中以每分钟20℃的速率加热到700℃时至少保留其纤维重量的10％，和
(iii)15-25重量份粘合剂材料；
弹性层，所述弹性层包括
(i)0-50重量份改良丙烯酸纤维，
(ii)50-85重量份聚酯纤维，和
(iii)15-25重量份粘合剂材料；
基于基层和弹性层的总重量，该基层占棉胎的20-70重量份，弹性层占棉胎的80-30重量份，棉胎的总厚度是1.25厘米(0.5英寸)或以上，
b)将所述层缝制在一起，形成防火被褥或者装饰织物，和
c)将防火被褥或者装饰织物结合到制品中。
25、权利要求23的方法，其中所述制品是床垫。
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| US10/807,068 US20050210584A1 (en) | 2004-03-23 | 2004-03-23 | Layered high loft flame resistant batting, articles containing said batting, and process for making same |
| US10/807,068 | 2004-03-23 |
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| Publication Number | Publication Date |
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| CN1933750A true CN1933750A (zh) | 2007-03-21 |
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| US (1) | US20050210584A1 (zh) |
| EP (1) | EP1727448A2 (zh) |
| JP (1) | JP2007530805A (zh) |
| KR (1) | KR20060134115A (zh) |
| CN (1) | CN1933750A (zh) |
| BR (1) | BRPI0508775A (zh) |
| CA (1) | CA2557477A1 (zh) |
| WO (1) | WO2005094634A2 (zh) |
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| CN104080601A (zh) * | 2012-01-24 | 2014-10-01 | 瑞泰控股公司 | 耐火绝热挠性墙板 |
| CN111086081A (zh) * | 2019-12-20 | 2020-05-01 | 江苏肯帝亚森工科技股份有限公司 | 一种防火性门板的制备工艺 |
| CN112497855A (zh) * | 2020-11-09 | 2021-03-16 | 湖南艾佳家纺有限责任公司 | 一种高弹定型棉胎及其生产工艺 |
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- 2004-03-23 US US10/807,068 patent/US20050210584A1/en not_active Abandoned
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- 2005-03-21 WO PCT/US2005/009282 patent/WO2005094634A2/en not_active Application Discontinuation
- 2005-03-21 EP EP05733624A patent/EP1727448A2/en not_active Withdrawn
- 2005-03-21 BR BRPI0508775-9A patent/BRPI0508775A/pt not_active IP Right Cessation
- 2005-03-21 CN CNA2005800090204A patent/CN1933750A/zh active Pending
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- 2005-03-21 JP JP2007505049A patent/JP2007530805A/ja active Pending
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN104080601A (zh) * | 2012-01-24 | 2014-10-01 | 瑞泰控股公司 | 耐火绝热挠性墙板 |
| CN111086081A (zh) * | 2019-12-20 | 2020-05-01 | 江苏肯帝亚森工科技股份有限公司 | 一种防火性门板的制备工艺 |
| CN111086081B (zh) * | 2019-12-20 | 2021-07-30 | 江苏从一家居股份有限公司 | 一种防火性门板的制备工艺 |
| CN112497855A (zh) * | 2020-11-09 | 2021-03-16 | 湖南艾佳家纺有限责任公司 | 一种高弹定型棉胎及其生产工艺 |
Also Published As
| Publication number | Publication date |
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| KR20060134115A (ko) | 2006-12-27 |
| BRPI0508775A (pt) | 2007-09-04 |
| WO2005094634A3 (en) | 2005-11-10 |
| JP2007530805A (ja) | 2007-11-01 |
| US20050210584A1 (en) | 2005-09-29 |
| CA2557477A1 (en) | 2005-10-13 |
| WO2005094634A2 (en) | 2005-10-13 |
| EP1727448A2 (en) | 2006-12-06 |
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