EP1498523A1 - Interlaced fabric with high flame retardancy - Google Patents
Interlaced fabric with high flame retardancy Download PDFInfo
- Publication number
- EP1498523A1 EP1498523A1 EP03745003A EP03745003A EP1498523A1 EP 1498523 A1 EP1498523 A1 EP 1498523A1 EP 03745003 A EP03745003 A EP 03745003A EP 03745003 A EP03745003 A EP 03745003A EP 1498523 A1 EP1498523 A1 EP 1498523A1
- Authority
- EP
- European Patent Office
- Prior art keywords
- yarn
- fiber
- halogen
- weight
- flame resistant
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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Classifications
-
- D—TEXTILES; PAPER
- D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
- D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
- D01F6/00—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof
- D01F6/28—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from copolymers obtained by reactions only involving carbon-to-carbon unsaturated bonds
- D01F6/40—Modacrylic fibres, i.e. containing 35 to 85% acrylonitrile
-
- D—TEXTILES; PAPER
- D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
- D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
- D01F1/00—General methods for the manufacture of artificial filaments or the like
- D01F1/02—Addition of substances to the spinning solution or to the melt
- D01F1/07—Addition of substances to the spinning solution or to the melt for making fire- or flame-proof filaments
-
- D—TEXTILES; PAPER
- D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
- D02G—CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
- D02G3/00—Yarns or threads, e.g. fancy yarns; Processes or apparatus for the production thereof, not otherwise provided for
- D02G3/44—Yarns or threads characterised by the purpose for which they are designed
- D02G3/443—Heat-resistant, fireproof or flame-retardant yarns or threads
-
- D—TEXTILES; PAPER
- D03—WEAVING
- D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
- D03D15/00—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used
- D03D15/50—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the properties of the yarns or threads
- D03D15/513—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the properties of the yarns or threads heat-resistant or fireproof
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
- Y10T442/30—Woven fabric [i.e., woven strand or strip material]
- Y10T442/3179—Woven fabric is characterized by a particular or differential weave other than fabric in which the strand denier or warp/weft pick count is specified
- Y10T442/3293—Warp and weft are identical and contain at least two chemically different strand materials
Definitions
- the present invention relates to a flame resistant union fabric. Specifically, the present invention relates to a union fabric having high degree of flame resistance consisting of a compound yarn having a halogen-containing flame resistant fiber including an antimony compound as a principal component, and a cellulosic fiber.
- Japanese Patent No. 2593985 specification and Japanese Patent No. 2593986 specification disclose a method of using antimony compounds as a flame resistant agent to be added to the halogen-containing flame resistant fibers in compounding of halogen-containing flame resistant fibers and natural fibers.
- union fabrics using general-purpose cellulosic fibers as a warp yarn and a halogen-containing flame resistant fiber including antimony compounds as a weft yarn are often used for interior design products, such as curtains and chair coverings, because special features of cellulosic fibers, such as natural feeling, hygroscopic property, and heat resistance, can be exhibited.
- union fabrics using cellulosic fibers as a warp yarn and halogen-containing flame resistant fibers including antimony compounds as a weft yarn, such as jacquard, dobby, and satin have special feature with many cellulosic fibers disposed on a surface side of the fabric.
- the fiber has a cost higher than that of conventional fibers as compared with independent addition of the antimony compounds to the halogen-containing fiber, leading to a problem of higher cost of the union fabric.
- a union fabric comprising a halogen-containing fiber by addition of only antimony compounds and a general-purpose fiber, such as a cellulosic fiber
- development of a union fabric exhibiting high flame resistance and classified in Class M1 of NF P 92-503 combustion test without combined use of zinc stannate compounds etc. has been long awaited.
- the present invention aims at providing a fabric having high degree of flame resistance in case of union fabrics consisting of halogen-containing flame resistant fibers and cellulosic fibers, and classified in class M1 of NF P 92-503 combustion test.
- the present inventors performed repeated investigation about union fabrics consisting of modacrylic flame resistant fibers as halogen-containing flame resistant fibers, and cellulosic fibers. As a result, it was found out that when a compound yarn using a modacrylic fiber, compounded with other fibers, including antimony compound as a principal component shows a certain specific thermal behavior, use of the compound yarn as a warp yarn or a weft yarn might exhibit high flame resistance in union fabrics, such as jacquard, dobby, and satin weave.
- the present invention relates to a flame resistant union fabric obtained by co-weaving: 30% to 70% by weight of a compound yarn (A) obtained by compounding a halogen-containing flame resistant fiber (a-1) including 25 parts (hereinafter abbreviated as simply part) to 50 parts of an antimony compound into 100 parts of an acrylic based copolymer obtained by copolymerizing a monomer mixture comprising 30% to 70% by weight (hereinafter abbreviated as simply %) acrylonitrile, 30% to 70% of a halogen containing vinyl based monomer, and 0% to 10% of a vinyl based monomer copolymerizable therewith, with another fiber (a-2), the compound yarn (A) having less than 5% of elongation under a condition of a load of 300 mg/metric count of No. 17, and of a temperature range of 100 degrees C to 500 degrees C; and 70% to 30% by weight of a cellulosic fiber yarn (B).
- a compound yarn (A) obtained by compounding a hal
- the flame resistant union fabric is preferably a union fabric wherein the cellulosic fiber (B) is at least one kind selected from a group consisting of cotton, hemp, rayon, polynosic, cupra, acetate, and triacetate.
- the present invention relates a flame resistant union fabric obtained by compounding:
- a fiber yarn including a halogen-containing flame resistant fiber (a-1) is a fiber used in order to give flame resistance to a union fabric of the present invention.
- the halogen-containing flame resistant fiber (a-1) consists of a composition including an antimony compound in an acrylic based copolymer obtained by polymerizing a monomer mixture including 30% to 70% acrylonitrile, 30% to 70% of a halogen containing vinyl based monomer, and 0% to 10% of a vinyl based monomer copolymerizable with the acrylonitrile and the halogen containing vinyl based monomer (hereinafter referred to as copolymerizable vinyl based monomer).
- a percentage of the acrylonitrile is not less than 30%, and preferably not less than 40% (lower limit), and it is not more than 70%, and preferably not more than 60% (upper limit).
- a percentage of the halogen containing vinyl based monomer is not less than 30%, and preferably not less than 40% (lower limit), and it is not more than 70%, and preferably not more than 60% (upper limit).
- a percentage of the copolymerizable vinyl based monomer is preferably not less than 1% (lower limit) , and it is not more than 10%, and preferably not more than 5% (upper limit).
- the total percentage of the acrylonitrile, the halogen containing vinyl based monomer, and the copolymerizable vinyl based monomer is adjusted so as to give 100%.
- a percentage of the acrylonitrile of less than the lower limit or a percentage exceeding the upper limit of the halogen containing vinyl based monomer does not allow demonstration of sufficient heat-resistance, and a percentage exceeding the upper limit of the acrylonitrile unit or a percentage of the halogen containing vinyl based monomer of less than the lower limit gives inadequate flame resistance.
- a percentage exceeding the upper limit of the copolymerizable vinyl based monomer fails to fully exhibit flame resistance and touch that are special features of the halogen-containing flame resistant fiber.
- halogen containing vinyl based monomers can be used, as long as the halogen containing vinyl based monomer is a vinyl based monomer including halogen atom, preferably bromine atom or chlorine atom.
- halogen containing vinyl based monomer for example, vinyl chloride, vinylidene chloride, vinyl bromide, etc. may be mentioned. These may be used independently or two or more kinds may be used in combination.
- the copolymerizable vinyl based monomer for example, there may be mentioned: acrylic acid; acrylic esters, such as ethyl acrylate, and propyl acrylate; methacrylic acid; methacrylic esters, such as methyl methacrylate, and ethyl methacrylate; and furthermore, acrylamide, vinyl acetate, vinyl sulfonic acid, vinyl sulfonate (sodium vinyl sulfonate etc.), styrene sulfonic acid, styrene sulfonate (sodium styrene sulfonate etc.) These may be used independently or two or more kinds may be used in combination.
- any methods such as usual vinyl polymerization methods, for example, a slurry polymerization method, an emulsion polymerization method, a solution polymerization method, etc., may be adopted without special limitation.
- antimony compound for example, inorganic antimony compounds, such as antimony trioxide, antimony pentoxide, antimonic acid, and antimony oxychloride may be mentioned. These may be used independently or two or more kinds may be used in combination.
- a content of the antimony compound is not less than 25 parts to 100 parts of the acrylic based copolymer, and preferably not less than 30 parts (lower limit), and it is not more than 50 parts (upper limit).
- a content of the antimony compound of less than the lower limit disables sufficient guarantee of flame resistance of a compounded flame resistant union fabric.
- an amount of the antimony compound exceeding the upper limit reduces physical properties, such as strength and elongation, of the halogen-containing flame resistant fiber, leading to problems, such as nozzle clogging during manufacturing process.
- halogen-containing flame resistant fiber As methods of adding the antimony compound, as a flame resistant agent, to the acrylic based copolymer to obtain a composition (halogen-containing flame resistant fiber), there may be mentioned: a method of dissolving the acrylic based copolymer in a solvent that can dissolve the copolymer and then of mixing and dispersing the flame resistant agent into the obtained solution to manufacture a fiber; and a method of immersing a fiber obtained from the acrylic based copolymer into an aqueous binder solution including a flame resistant agent and then squeezing, drying, and heat treating to impregnate the flame resistant agent using after treatment technique etc.
- Methods for obtaining a halogen-containing flame resistant fiber are not limited to them, and other well-known methods may be used.
- a compound yarn (A) obtained by compounding a halogen-containing flame resistant fiber (a-1) and another fiber (a-2) is a compound yarn having less than 5% of elongation percentage under conditions of a load of 300 mg/metric count of No. 17 and of a temperature range of 100 degrees C to 500 degrees C
- the other fiber (a-2) compounded with the halogen-containing flame resistant fiber (a-1) is not especially limited.
- An elongation percentage is more preferably not more than 3%. Since not less than 5% of elongation percentage of the compound yarn (A) reduces heat resistance and flame resistance, leading to formation of a hole in a textile fabric when ignited.
- an elongation percentage of the compound yarn (A) is obtained by measuring a sample length under a fixed load of 300 mg/metric count of No. 17, when a temperature is raised from 100 degrees C to 500 degrees C at a rate of 100-degree C/minute using SSC150 (manufactured by Seiko Instruments Inc.).
- An elongation percentage is defined as a ratio of a difference between a sample length at the time of a maximum elongation at 100 degrees C to 500 degrees C, and an original sample length, with respect to an original sample length.
- a compound yarn (A) having an elongation percentage of less than 5% of thermal behavior under conditions of a load of 300 mg/metric count of No. 17, and of a temperature range of 100 degrees C to 500 degrees C may be obtained, cotton, rayon, aramid fibers, nylon fibers, etc. are preferable as the other fiber (a-2). Since especially natural touch of the fabric can fully be exhibited, cotton and rayon are preferable.
- a percentage of the halogen-containing flame resistant fiber (a-1) is preferably 60 parts to 95 parts in the compound yarn (A), and more preferably 70 parts to 80 parts. And a percentage of the other fiber (a-2) is preferably 40 parts to 5 parts in the compound yarn (A), and more preferably 30 parts to 20 parts.
- the halogen-containing flame resistant fiber (a-1) and the other fiber (a-2) are compounded so as to be 100 parts in total.
- halogen-containing flame resistant fiber (a-1) There is shown a tendency for an amount of the halogen-containing flame resistant fiber (a-1) of less than 60 parts to reduce a content of the halogen-containing fiber exhibiting flame resistance in the fabric, resulting in decrease in flame resistance. There is also shown a tendency for an amount exceeding 95 parts of the halogen-containing flame resistant fiber (a-1) to melt the compound yarn (A) to easily form a hole in the fabric during combustion test, also resulting in decrease in flame resistance.
- Compounding methods of the halogen-containing flame resistant fiber (a-1) and the other fiber (a-2) are not especially limited, and blending, twisting, etc. may be mentioned.
- the cellulosic fiber yarn (B) can be used without special limitation.
- at least one kind of yarn selected from a group consisting of cotton, hemp, rayon, polynosic, cupra, acetate, and triacetate is preferable.
- cotton is preferable among them.
- a flame resistant union fabric of the present invention is manufactured by co-weaving of the compound yarn (A) and the cellulosic fiber yarn (B) for giving heat-resistance and natural touch.
- the flame resistant union fabric of the present invention is obtained by co-weaving one of the compound yarn (A) and the cellulosic fiber yarn (B) for a warp yarn, and another for a weft yarn, respectively.
- Union fabric itself is a fabric excellent in design having very characteristic appearance, and especially in co-weaving of the flame resistant fiber and general non-flame resistant fibers, some certain weaving methods enable a large amount of disposition on a fabric surface of non-flame resistant fibers with excellent touch or hygroscopic property, enabling increase in commercial value of the fabric.
- union fabrics that dispose much non-flame resistant fibers to a fabric surface thereof have low flame resistance in general as compared with that of plain fabrics.
- a union fabric of the present invention obtained by co-weaving the compound yarn (A) and the cellulosic fiber yarn (B) uses the compound yarn (A) obtained by compounding the halogen-containing flame resistant fiber (a-1) and the other fiber (a-2), and thereby while maintaining high degree of flame resistance of class M1 also in a union fabric, the union fabric allows disposition of a large amount of cotton (B) in the fabric surface, enabling realization of a fabric having high design property, excellent touch, and excellent hygroscopic property.
- compounding of not only the halogen-containing flame resistant fiber but the other fiber (a-2) as the compound yarn (A) may suppress contraction by heat, promote carbonization, and improve flame resistance. Furthermore, both special features such as flame resistance of the compound yarn (A), and touch of the cellulosic fiber yarn (B) will be maximized.
- a percentage of the compound yarn (A) is not less than 30%, and preferably not less than 40% (lower limit), and not more than 70%, and preferably not more than 60% (upper limit).
- a percentage of the cellulosic fiber yarn (B) is not less than 30%, and preferably not less than 40% (lower limit), and it is not more than 70%, and preferably not more than 60% (upper limit).
- a total of the compound yarn (A) and the cellulosic fiber yarn (B) is adjusted to be 100% by weight.
- a percentage of the compound yarn (A) of less than the lower limit in the flame resistant union fabric fails to provide sufficient flame resistance, and on the other hand, a percentage exceeding the upper limit fails to fully exhibit special feature as a flame resistant fiber of the fiber yarn (B).
- Combustion of a union fabric was carried out in four directions of: warp surface side, warp reverse side, weft surface side, and weft reverse side. Judgment was performed according to following NF P 92-507 criteria.
- a sample length to the original sample length was measured when a testing temperature was raised from 100 degrees C to 500 degrees C in a rate of 100-degree C/minute under a fixed load of 300 mg/metric count of No. 17.
- An elongation percentage is defined as a ratio of a difference between a sample length at the time of a maximum elongation at 100 degrees C to 500 degrees C, and an original sample length to an original sample length.
- the obtained filaments were drawn 3 times at 150 degrees C, and subsequently heat-treated for 30 seconds at 175 degrees C to obtain a halogen-containing flame resistant fiber having a size of a fiber of 3 dtex.
- a finishing oil for spinning (manufactured by TAKEMOTO OIL & FAT CO., LTD.) was added to the obtained halogen-containing flame resistant fiber, textured to form crimps, and subsequently cut into a length of 38 mm.
- 80 parts of the cut halogen-containing flame resistant fiber and 20 parts of cotton were mixed in a state of raw fiber so as to be a total of 100 parts to manufacture a spun yarn having a metric count of No. 17.
- Table 1 shows elongation percentage of obtained compound yarn.
- a halogen-containing flame resistant fiber was manufactured in a same manner as in Manufacturing Example 1, and a spun yarn having a metric count of No. 17 was obtained without mixing cellulosic fiber.
- Table 1 shows elongation percentage of obtained compound yarn. Examples 1 to 6
- compound yarns (A) in Manufacturing Examples 1, 2, or 3 using the halogen-containing flame resistant fiber including antimony trioxide as a flame resistant agent and cotton have 0% of elongation percentage at 500 degrees C.
- combustion test results of union fabrics in Examples 1, 2, or 3 manufactured using the compound yarns (A) and spun yarn (B) of cotton has class M1, showing high flame resistance.
- combustion test results have class M1 to show high flame resistance.
- a union fabric consisting of a compound yarn obtained by compounding a halogen-containing flame resistant fiber including antimony trioxide and another fiber, and a cellulosic fiber yarn can give a fabric having high flame resistance classified into class M1.
- a flame resistant union fabric of the present invention is a union fabric having high degree of flame resistance that may pass class M1 of NF P 92-503 combustion test in France, it can develop high flame resistance also in union fabrics, such as jacquard, dobby, and satin weave.
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- Textile Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Chemical Kinetics & Catalysis (AREA)
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Abstract
A fabric is provided that has high degree of flame resistance
in the case of a union fabric consisting of a halogen-containing flame
resistant fiber including antimony compounds (A), and a cellulosic
fiber, and the fabric is classified into class M1 of NF P 92-503
combustion test in France.
A flame resistant union fabric obtained by co-weaving: 30% to
70% by weight of a compound yarn (A) obtained by compounding a
halogen-containing flame resistant fiber (a-1) including 25 to
50 parts by weight of an antimony compound in 100 parts by
weight of an acrylic based copolymer obtained by polymerizing
a monomer mixture including 30 to 70% by weight acrylonitrile,
30 to 70% by weight of a halogen containing vinyl based
monomer, and 0 to 10% by weight of a vinyl based monomer
copolymerizable therewith, and another fiber (a-2), the
compound yarn (A) having an elongation percentage of less than
5% under a condition of a load of 300 mg/metric count of No.
17, and of a temperature range of 100 degrees C to 500 degrees
C; 70 to 30% by weight of a cellulosic fiber yarn (B).
Description
The present invention relates to a flame resistant union fabric.
Specifically, the present invention relates to a union fabric having
high degree of flame resistance consisting of a compound yarn having
a halogen-containing flame resistant fiber including an antimony
compound as a principal component, and a cellulosic fiber.
In recent years, demand for guarantee of safety of foods, clothes
and housings has become stronger, and necessity for fire-resistant
materials is increasing. In such a situation, a plurality of methods
to give flame resistance to a flammable yarn by compounding
general-purpose flammable fibers and flame resistant fibers having
high degree of flame resistance, while maintaining characteristics
of the flammable yarn, have been proposed. As such a compound fiber,
for example, Japanese Patent No. 2593985 specification and Japanese
Patent No. 2593986 specification disclose a method of using antimony
compounds as a flame resistant agent to be added to the
halogen-containing flame resistant fibers in compounding of
halogen-containing flame resistant fibers and natural fibers.
Recently, union fabrics using general-purpose cellulosic fibers
as a warp yarn and a halogen-containing flame resistant fiber including
antimony compounds as a weft yarn are often used for interior design
products, such as curtains and chair coverings, because special
features of cellulosic fibers, such as natural feeling, hygroscopic
property, and heat resistance, can be exhibited. Among them, union
fabrics using cellulosic fibers as a warp yarn and halogen-containing
flame resistant fibers including antimony compounds as a weft yarn,
such as jacquard, dobby, and satin have special feature with many
cellulosic fibers disposed on a surface side of the fabric.
However, in these union fabrics, uneven existence of cellulosic
fibers and halogen-containing flame resistant fibers in a fabric makes
it very difficult to pass a highest flame resistant class M1 in NF
P 92-503 combustion test in France that requires a very high degree
of flame resistance.
Only international publication No. 01/32968 pamphlet proposes
a method applying such technique furthermore in which a union fabric
using a cellulosic fiber as a warp yarn and a halogen-containing fiber
having an antimony compound and a zinc stannate compound added therein
in combination as a weft yarn has a very high flame resistance passing
Class M1 of NF P 92-503 combustion test.
However, since zinc stannate compounds have a higher cost than
that of antimony compounds, the fiber has a cost higher than that of
conventional fibers as compared with independent addition of the
antimony compounds to the halogen-containing fiber, leading to a
problem of higher cost of the union fabric.
Accordingly, in a union fabric comprising a halogen-containing
fiber by addition of only antimony compounds and a general-purpose
fiber, such as a cellulosic fiber, development of a union fabric
exhibiting high flame resistance and classified in Class M1 of NF P
92-503 combustion test without combined use of zinc stannate compounds
etc. has been long awaited.
The present invention aims at providing a fabric having high
degree of flame resistance in case of union fabrics consisting of
halogen-containing flame resistant fibers and cellulosic fibers, and
classified in class M1 of NF P 92-503 combustion test.
The present inventors performed repeated investigation about
union fabrics consisting of modacrylic flame resistant fibers as
halogen-containing flame resistant fibers, and cellulosic fibers. As
a result, it was found out that when a compound yarn using a modacrylic
fiber, compounded with other fibers, including antimony compound as
a principal component shows a certain specific thermal behavior, use
of the compound yarn as a warp yarn or a weft yarn might exhibit high
flame resistance in union fabrics, such as jacquard, dobby, and satin
weave.
That is, the present invention relates to a flame resistant
union fabric obtained by co-weaving: 30% to 70% by weight of a
compound yarn (A) obtained by compounding a halogen-containing
flame resistant fiber (a-1) including 25 parts (hereinafter
abbreviated as simply part) to 50 parts of an antimony
compound into 100 parts of an acrylic based copolymer obtained
by copolymerizing a monomer mixture comprising 30% to 70% by
weight (hereinafter abbreviated as simply %) acrylonitrile,
30% to 70% of a halogen containing vinyl based monomer, and 0%
to 10% of a vinyl based monomer copolymerizable therewith,
with another fiber (a-2), the compound yarn (A) having less
than 5% of elongation under a condition of a load of 300
mg/metric count of No. 17, and of a temperature range of 100
degrees C to 500 degrees C; and 70% to 30% by weight of a
cellulosic fiber yarn (B).
The flame resistant union fabric is preferably a union fabric
wherein the cellulosic fiber (B) is at least one kind selected from
a group consisting of cotton, hemp, rayon, polynosic, cupra, acetate,
and triacetate.
The present invention relates a flame resistant union fabric
obtained by compounding:
In the present invention, a fiber yarn including a
halogen-containing flame resistant fiber (a-1) is a fiber used in order
to give flame resistance to a union fabric of the present invention.
The halogen-containing flame resistant fiber (a-1) consists of a
composition including an antimony compound in an acrylic based
copolymer obtained by polymerizing a monomer mixture including
30% to 70% acrylonitrile, 30% to 70% of a halogen containing
vinyl based monomer, and 0% to 10% of a vinyl based monomer
copolymerizable with the acrylonitrile and the halogen
containing vinyl based monomer (hereinafter referred to as
copolymerizable vinyl based monomer).
In the monomer mixture used for obtaining the acrylic based
copolymer, a percentage of the acrylonitrile is not less than 30%,
and preferably not less than 40% (lower limit), and it is not more
than 70%, and preferably not more than 60% (upper limit).
In the monomer mixture, a percentage of the halogen containing
vinyl based monomer is not less than 30%, and preferably not less than
40% (lower limit), and it is not more than 70%, and preferably not
more than 60% (upper limit).
In the monomer mixture, a percentage of the copolymerizable
vinyl based monomer is preferably not less than 1% (lower limit) , and
it is not more than 10%, and preferably not more than 5% (upper limit).
Of course, the total percentage of the acrylonitrile, the halogen
containing vinyl based monomer, and the copolymerizable vinyl based
monomer is adjusted so as to give 100%.
In the monomer mixture, a percentage of the acrylonitrile of
less than the lower limit or a percentage exceeding the upper limit
of the halogen containing vinyl based monomer does not allow
demonstration of sufficient heat-resistance, and a percentage
exceeding the upper limit of the acrylonitrile unit or a percentage
of the halogen containing vinyl based monomer of less than the lower
limit gives inadequate flame resistance. In the monomer mixture, a
percentage exceeding the upper limit of the copolymerizable vinyl
based monomer fails to fully exhibit flame resistance and touch that
are special features of the halogen-containing flame resistant fiber.
Any halogen containing vinyl based monomers can be used, as long
as the halogen containing vinyl based monomer is a vinyl based monomer
including halogen atom, preferably bromine atom or chlorine atom.
As examples of the halogen containing vinyl based monomer, for example,
vinyl chloride, vinylidene chloride, vinyl bromide, etc. may be
mentioned. These may be used independently or two or more kinds may
be used in combination.
As the copolymerizable vinyl based monomer, for example, there
may be mentioned: acrylic acid; acrylic esters, such as ethyl acrylate,
and propyl acrylate; methacrylic acid; methacrylic esters, such as
methyl methacrylate, and ethyl methacrylate; and furthermore,
acrylamide, vinyl acetate, vinyl sulfonic acid, vinyl sulfonate
(sodium vinyl sulfonate etc.), styrene sulfonic acid, styrene
sulfonate (sodium styrene sulfonate etc.) These may be used
independently or two or more kinds may be used in combination.
As methods of obtaining the acrylic based copolymer by
polymerization of the monomer mixture including the acrylonitrile,
halogen containing monomer, and the monomer copolymerizable
therewith, any methods, such as usual vinyl polymerization methods,
for example, a slurry polymerization method, an emulsion
polymerization method, a solution polymerization method, etc., may
be adopted without special limitation.
As preferable examples of the antimony compound, for example,
inorganic antimony compounds, such as antimony trioxide, antimony
pentoxide, antimonic acid, and antimony oxychloride may be mentioned.
These may be used independently or two or more kinds may be used in
combination.
A content of the antimony compound is not less than 25 parts
to 100 parts of the acrylic based copolymer, and preferably not less
than 30 parts (lower limit), and it is not more than 50 parts (upper
limit). A content of the antimony compound of less than the lower
limit disables sufficient guarantee of flame resistance of a
compounded flame resistant union fabric. And on the other hand, an
amount of the antimony compound exceeding the upper limit reduces
physical properties, such as strength and elongation, of the
halogen-containing flame resistant fiber, leading to problems, such
as nozzle clogging during manufacturing process.
As methods of adding the antimony compound, as a flame resistant
agent, to the acrylic based copolymer to obtain a composition
(halogen-containing flame resistant fiber), there may be mentioned:
a method of dissolving the acrylic based copolymer in a solvent that
can dissolve the copolymer and then of mixing and dispersing the flame
resistant agent into the obtained solution to manufacture a fiber;
and a method of immersing a fiber obtained from the acrylic based
copolymer into an aqueous binder solution including a flame resistant
agent and then squeezing, drying, and heat treating to impregnate the
flame resistant agent using after treatment technique etc. Methods
for obtaining a halogen-containing flame resistant fiber are not
limited to them, and other well-known methods may be used.
As long as a compound yarn (A) obtained by compounding a
halogen-containing flame resistant fiber (a-1) and another fiber
(a-2) is a compound yarn having less than 5% of elongation percentage
under conditions of a load of 300 mg/metric count of No. 17 and of
a temperature range of 100 degrees C to 500 degrees C, the other fiber
(a-2) compounded with the halogen-containing flame resistant fiber
(a-1) is not especially limited. An elongation percentage is more
preferably not more than 3%. Since not less than 5% of elongation
percentage of the compound yarn (A) reduces heat resistance and flame
resistance, leading to formation of a hole in a textile fabric when
ignited.
Here, an elongation percentage of the compound yarn (A) is
obtained by measuring a sample length under a fixed load of 300
mg/metric count of No. 17, when a temperature is raised from 100 degrees
C to 500 degrees C at a rate of 100-degree C/minute using SSC150
(manufactured by Seiko Instruments Inc.). An elongation percentage
is defined as a ratio of a difference between a sample length at the
time of a maximum elongation at 100 degrees C to 500 degrees C, and
an original sample length, with respect to an original sample length.
Since a compound yarn (A) having an elongation percentage of less
than 5% of thermal behavior under conditions of a load of 300 mg/metric
count of No. 17, and of a temperature range of 100 degrees C to 500
degrees C may be obtained, cotton, rayon, aramid fibers, nylon fibers,
etc. are preferable as the other fiber (a-2). Since especially natural
touch of the fabric can fully be exhibited, cotton and rayon are
preferable.
A percentage of the halogen-containing flame resistant fiber
(a-1) is preferably 60 parts to 95 parts in the compound yarn (A),
and more preferably 70 parts to 80 parts. And a percentage of the
other fiber (a-2) is preferably 40 parts to 5 parts in the compound
yarn (A), and more preferably 30 parts to 20 parts. The
halogen-containing flame resistant fiber (a-1) and the other fiber
(a-2) are compounded so as to be 100 parts in total.
There is shown a tendency for an amount of the halogen-containing
flame resistant fiber (a-1) of less than 60 parts to reduce a content
of the halogen-containing fiber exhibiting flame resistance in the
fabric, resulting in decrease in flame resistance. There is also shown
a tendency for an amount exceeding 95 parts of the halogen-containing
flame resistant fiber (a-1) to melt the compound yarn (A) to easily
form a hole in the fabric during combustion test, also resulting in
decrease in flame resistance.
Compounding methods of the halogen-containing flame resistant
fiber (a-1) and the other fiber (a-2) are not especially limited, and
blending, twisting, etc. may be mentioned.
The cellulosic fiber yarn (B) can be used without special
limitation. As examples, in view of fully exhibiting natural touch,
at least one kind of yarn selected from a group consisting of cotton,
hemp, rayon, polynosic, cupra, acetate, and triacetate is preferable.
In view of many advantages, such as washing resistance, dye affinity,
and low cost, especially cotton is preferable among them.
A flame resistant union fabric of the present invention is
manufactured by co-weaving of the compound yarn (A) and the cellulosic
fiber yarn (B) for giving heat-resistance and natural touch.
The flame resistant union fabric of the present invention is
obtained by co-weaving one of the compound yarn (A) and the cellulosic
fiber yarn (B) for a warp yarn, and another for a weft yarn,
respectively.
Union fabric itself is a fabric excellent in design having very
characteristic appearance, and especially in co-weaving of the flame
resistant fiber and general non-flame resistant fibers, some certain
weaving methods enable a large amount of disposition on a fabric
surface of non-flame resistant fibers with excellent touch or
hygroscopic property, enabling increase in commercial value of the
fabric. However, union fabrics that dispose much non-flame resistant
fibers to a fabric surface thereof have low flame resistance in general
as compared with that of plain fabrics. A union fabric of the present
invention obtained by co-weaving the compound yarn (A) and the
cellulosic fiber yarn (B) uses the compound yarn (A) obtained by
compounding the halogen-containing flame resistant fiber (a-1) and
the other fiber (a-2), and thereby while maintaining high degree of
flame resistance of class M1 also in a union fabric, the union fabric
allows disposition of a large amount of cotton (B) in the fabric
surface, enabling realization of a fabric having high design property,
excellent touch, and excellent hygroscopic property. In the union
fabric, compounding of not only the halogen-containing flame resistant
fiber but the other fiber (a-2) as the compound yarn (A) may suppress
contraction by heat, promote carbonization, and improve flame
resistance. Furthermore, both special features such as flame
resistance of the compound yarn (A), and touch of the cellulosic fiber
yarn (B) will be maximized.
In the flame resistant union fabric, a percentage of the compound
yarn (A) is not less than 30%, and preferably not less than 40% (lower
limit), and not more than 70%, and preferably not more than 60% (upper
limit). On the other hand, in the flame resistant union fabric a
percentage of the cellulosic fiber yarn (B) is not less than 30%, and
preferably not less than 40% (lower limit), and it is not more than
70%, and preferably not more than 60% (upper limit).
Of course, a total of the compound yarn (A) and the cellulosic
fiber yarn (B) is adjusted to be 100% by weight.
A percentage of the compound yarn (A) of less than the lower
limit in the flame resistant union fabric fails to provide sufficient
flame resistance, and on the other hand, a percentage exceeding the
upper limit fails to fully exhibit special feature as a flame resistant
fiber of the fiber yarn (B).
Reasons that a flame resistant fiber union fabric of the present
invention represents high flame resistance of class M1 in NF P 92-503
combustion test are not yet certain, but for example, following reasons
can be conceivable.
Evaluation of flame resistance of union fabrics was performed
according to French NF P 92-503 method. The French NF P 92-503
combustion test method will be briefly described. Examined fabric
is held horizontally inclined by 30 degrees, an electric heater with
500 W is brought close to the fabric, and contact with a burner flame
is carried out for 5 seconds at each timing of 20 seconds, 45 seconds,
75 seconds, 105 seconds, 135 seconds, and 165 seconds after heater
heating starts. Flame resistance is judged by a number of seconds
in which a flame remains burning, and a distance of charring. This
examination is a very severe combustion test in which contact with
a burner flame is carried out simultaneously with heating by an
electric heater.
Combustion of a union fabric was carried out in four directions
of: warp surface side, warp reverse side, weft surface side, and weft
reverse side. Judgment was performed according to following NF P
92-507 criteria.
Using SSC150 (manufactured by Seiko Instruments Inc.) , a sample
length to the original sample length was measured when a testing
temperature was raised from 100 degrees C to 500 degrees C in a rate
of 100-degree C/minute under a fixed load of 300 mg/metric count of
No. 17. An elongation percentage is defined as a ratio of a difference
between a sample length at the time of a maximum elongation at 100
degrees C to 500 degrees C, and an original sample length to an original
sample length.
52 parts acrylonitrile, 46.8 parts vinylidene chloride, and
1.2 parts sodium styrenesulfonate were copolymerized to obtain
an acrylic based copolymer. The obtained acrylic based
copolymer was dissolved in acetone to obtain a solution with a
concentration of 30%. 50 parts antimony trioxide were added to
100 parts of the obtained copolymer to prepare a spinning
solution. The obtained spinning solution
was extruded into an aqueous solution of acetone with a concentration
of 38% at 25 degree C using a nozzle having 0.07 mm of pore size, and
33000 numbers of holes, and then after washing with water the obtained
filaments were dried for 8 minutes at 120 degrees C. Then the obtained
filaments were drawn 3 times at 150 degrees C, and subsequently
heat-treated for 30 seconds at 175 degrees C to obtain a
halogen-containing flame resistant fiber having a size of a fiber of
3 dtex. A finishing oil for spinning (manufactured by TAKEMOTO OIL
& FAT CO., LTD.) was added to the obtained halogen-containing flame
resistant fiber, textured to form crimps, and subsequently cut into
a length of 38 mm. Subsequently, 80 parts of the cut halogen-containing
flame resistant fiber and 20 parts of cotton were
mixed in a state of raw fiber so as to be a total of 100 parts
to manufacture a spun yarn having a metric count of No. 17.
Table 1 shows elongation percentage of obtained compound yarn.
Except mixing 30 parts of cotton to 70 parts of the halogen-containing
flame resistant fiber, a similar method as in
Manufacturing Example 1 was repeated to manufacture a compound
yarn and then a spun yarn having a metric count of No. 17 was
obtained. Table 1 shows elongation percentage of obtained
compound yarn.
Except for having mixed 40 parts of cotton to 60 parts of the
halogen-containing flame resistant fiber, a similar method
as in Manufacturing Example 1 was repeated to manufacture a compound
yarn and then a spun yarn having a metric count of No. 17 was
obtained. Table 1 shows elongation percentage of obtained
compound yarn.
Except for having mixed 20 parts of rayon to 80 parts of the
halogen-containing flame resistant fiber, a similar method
as in Manufacturing Example 1 was repeated to manufacture a compound
yarn and then a spun yarn having a metric count of No. 17 was
obtained. Table 1 shows elongation percentage of obtained
compound yarn.
Except for having mixed 30 parts of rayon to 70 parts of the
halogen-containing flame resistant fiber, a similar method
as in Manufacturing Example 1 was repeated to manufacture a compound
yarn and then a spun yarn having a metric count of No. 17 was
obtained. Table 1 shows elongation percentage of obtained
compound yarn.
Except for having mixed 40 parts of rayon to 60 parts of the
halogen-containing flame resistant fiber, a similar method as
in Manufacturing Example 1 was repeated to manufacture a
compound yarn and then a spun yarn having a metric count of
No. 17 was obtained. Table 1 shows elongation percentage of
obtained compound yarn.
A halogen-containing flame resistant fiber was manufactured in
a same manner as in Manufacturing Example 1, and a spun yarn having
a metric count of No. 17 was obtained without mixing cellulosic fiber.
Table 1 shows elongation percentage of obtained compound yarn.
Examples 1 to 6
Using a spun yarn of cotton with a metric count of No. 51
(percentage of the warp yarn 55%) as a warp yarn with a density of
155 units/2.54 cm (1 inch), compound spun yarns manufactured in the
Manufacturing Examples 1 to 6 were woven with a density of 42 units/2.54
cm (1 inch) (percentage of the weft yarn 45%) as weft yarns into union
fabrics having a 5 harness satin weave. The obtained union fabrics
were evaluated for flame resistance. Table 1 shows results.
Except for using a spun yarn manufactured in the
Comparative Manufacturing Example 1 as a weft yarn, union fabrics of
5 harness satin weave were manufactured in the same manner as in Examples
1 to 6. The obtained union fabric was evaluated for flame resistance.
Table 1 shows results.
| EXAMPLE Number | Compound yarn (A) | Mixture ratio of compound yarn (A) / cellulosic fiber yarn (B) in a union fabric | Flame resistance | |||
| Antimony content in Halogen-containing fiber (a-1) (part) | Other fiber (a-2) | Mixture ratio (a-1)/(a -2) | Elongation percentage (%) | |||
| 1 | 50 | Cotton | 80/20 | 0 | 45/55 | M1 |
| 2 | 50 | Cotton | 70/30 | 0 | 45/55 | M1 |
| 3 | 50 | Cotton | 60/40 | 0 | 45/55 | M1 |
| 4 | 50 | Rayon | 80/20 | 0 | 45/55 | M1 |
| 5 | 50 | Rayon | 70/30 | 0 | 45/55 | M1 |
| 6 | 50 | Rayon | 60/40 | 0 | 45/55 | M1 |
| Comparative Example | 50 | - | 100/0 | 35 | 45/55 | M2 |
As is clear with reference to Table 1, compound yarns (A) in
Manufacturing Examples 1, 2, or 3 using the halogen-containing flame
resistant fiber including antimony trioxide as a flame resistant agent
and cotton have 0% of elongation percentage at 500 degrees C. And
combustion test results of union fabrics in Examples 1, 2, or 3
manufactured using the compound yarns (A) and spun yarn (B) of cotton
has class M1, showing high flame resistance. Also in Examples 4, 5,
or 6 using rayon as a cellulosic fiber, combustion test results
have class M1 to show high flame resistance.
On the other hand, the spun yarn using only a halogen-containing
flame resistant fiber manufactured by the Comparative Manufacturing
Example 1, an elongation percentage at a temperature of 500 degrees
C shows 35%. The union fabric in Comparative Example 1 manufactured
using this compound yarn and a spun yarn of cotton has flame resistance
inferior to that of union fabrics obtained in Examples 1 to 6, showing
class M2.
As mentioned above, it may be understood that a union fabric
consisting of a compound yarn obtained by compounding a
halogen-containing flame resistant fiber including antimony trioxide
and another fiber, and a cellulosic fiber yarn can give a fabric having
high flame resistance classified into class M1.
Since a flame resistant union fabric of the present invention
is a union fabric having high degree of flame resistance that may pass
class M1 of NF P 92-503 combustion test in France, it can develop high
flame resistance also in union fabrics, such as jacquard, dobby, and
satin weave.
Claims (2)
- A flame resistant union fabric obtained by co-weaving: 30% to 70% by weight of a compound yarn (A) obtained by compounding a halogen-containing flame resistant fiber (a-1) including 25 to 50 parts by weight of an antimony compound in 100 parts by weight of an acrylic based copolymer obtained by polymerizing a monomer mixture including 30 to 70% by weight acrylonitrile, 30 to 70% by weight of a halogen containing vinyl based monomer, and 0 to 10% by weight of a vinyl based monomer copolymerizable therewith, and another fiber (a-2), the compound yarn (A) having an elongation percentage of less than 5% under a condition of a load of 300 mg/metric count of No. 17, and of a temperature range of 100 degrees C to 500 degrees C; 70 to 30% by weight of a cellulosic fiber yarn (B).
- The flame resistant union fabric according to Claim 1, wherein the cellulosic fiber yarn (B) consists of at least one kind selected from a group consisting of cotton, hemp, rayon, polynosic, cupra, acetate, and triacetate.
Applications Claiming Priority (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2002082711 | 2002-03-25 | ||
| JP2002082711 | 2002-03-25 | ||
| PCT/JP2003/003398 WO2003080909A1 (en) | 2002-03-25 | 2003-03-20 | Interlaced fabric with high flame retardancy |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| EP1498523A1 true EP1498523A1 (en) | 2005-01-19 |
| EP1498523A4 EP1498523A4 (en) | 2009-04-08 |
Family
ID=28449154
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| EP03745003A Withdrawn EP1498523A4 (en) | 2002-03-25 | 2003-03-20 | Interlaced fabric with high flame retardancy |
Country Status (5)
| Country | Link |
|---|---|
| US (1) | US20050130535A1 (en) |
| EP (1) | EP1498523A4 (en) |
| JP (1) | JPWO2003080909A1 (en) |
| CN (1) | CN1653220A (en) |
| WO (1) | WO2003080909A1 (en) |
Families Citing this family (9)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN102066625B (en) * | 2008-07-24 | 2013-03-13 | 株式会社钟化 | Flame-retardant synthetic fiber and flame-retardant fiber assembly, their production method, and fiber product |
| CN102677279A (en) * | 2012-05-29 | 2012-09-19 | 蔡紫林 | Fabric |
| CN102677360A (en) * | 2012-05-29 | 2012-09-19 | 蔡紫林 | Curtain fabric |
| CN102677334A (en) * | 2012-05-29 | 2012-09-19 | 蔡紫林 | Curtain fabric |
| CN102677290A (en) * | 2012-05-29 | 2012-09-19 | 蔡紫林 | Shell fabric |
| JP6158602B2 (en) * | 2013-06-11 | 2017-07-05 | 帝人株式会社 | Elastic flame retardant fabric and textile products |
| CN106435951B (en) * | 2016-09-26 | 2018-01-02 | 上海谐好安全科技有限公司 | Modacrylic Lyocell Nylon Blend Flame Retardant Fabric |
| EP4053318A4 (en) * | 2019-11-01 | 2023-01-04 | Asahi Kasei Advance Corporation | Flame retardant stretch fiber structure, flame retardant stretch woven/knitted fabric, flame retardant stretch core spun yarn, and protective clothing using same |
| CN111041659A (en) * | 2019-12-31 | 2020-04-21 | 正凯纺织有限公司 | Textile fabric with flame-retardant function and preparation method thereof |
Family Cites Families (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPS6189339A (en) * | 1984-10-05 | 1986-05-07 | 鐘淵化学工業株式会社 | Composite fire retardant fiber |
| EP0183014B1 (en) * | 1984-10-05 | 1994-02-02 | Kanegafuchi Kagaku Kogyo Kabushiki Kaisha | Flame-retarded fiber blend |
| JPH09296335A (en) * | 1996-05-07 | 1997-11-18 | Kanegafuchi Chem Ind Co Ltd | Flame-retardant fabric with improved strength and wash shrinkability |
| JPH10140478A (en) * | 1996-11-06 | 1998-05-26 | Kanegafuchi Chem Ind Co Ltd | Flame-retardant fabric and method for producing the same |
| JPH10280250A (en) * | 1997-04-07 | 1998-10-20 | Kanegafuchi Chem Ind Co Ltd | Flame retardant woven fabric with excellent coloring |
| WO2001032968A1 (en) * | 1999-11-04 | 2001-05-10 | Kaneka Corporation | Flame-retardant union fabric |
-
2003
- 2003-03-20 US US10/508,888 patent/US20050130535A1/en not_active Abandoned
- 2003-03-20 EP EP03745003A patent/EP1498523A4/en not_active Withdrawn
- 2003-03-20 JP JP2003578626A patent/JPWO2003080909A1/en active Pending
- 2003-03-20 WO PCT/JP2003/003398 patent/WO2003080909A1/en not_active Ceased
- 2003-03-20 CN CNA038112809A patent/CN1653220A/en active Pending
Also Published As
| Publication number | Publication date |
|---|---|
| US20050130535A1 (en) | 2005-06-16 |
| CN1653220A (en) | 2005-08-10 |
| WO2003080909A1 (en) | 2003-10-02 |
| EP1498523A4 (en) | 2009-04-08 |
| JPWO2003080909A1 (en) | 2005-07-28 |
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