FIELD OF THE INVENTION
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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.
BACKGROUND ART
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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.
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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.
SUMMARY OF THE INVENTION
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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.
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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).
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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.
BEST MODE FOR CARRYING-OUT THE INVENTION
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The present invention relates a flame resistant union fabric
obtained by compounding:
- 30% to 70% by weight of a compound yarn (A) obtained by
compounding a halogen-containing flame resistant fiber (a-1)
including 25 parts 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%
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).
-
-
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).
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
- (1) Use of compound yarn (A) that cannot easily be elongated
under temperatures of 100 degrees C to 500 degrees C during
heater-heating of combustion test suppresses contraction of the fabric
by heat, and promotes carbonization at the time of contact to a flame
of a heater to improve flame resistance.
- (2) Especially, mixing of fibers having thermal decomposition
temperatures higher than that of the halogen-containing fiber, such
as cotton, rayon, and aramid fibers, suppresses calorific power at
the time of contact to a flame of a heater.
-
EXAMPLE
(Flame resistance examination)
-
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.
Acceptance criteria
-
- M1: All flame-remaining periods in 4 directions are not more than 5
seconds
- M2: In examination in four directions, at least one sheet has a
flame-remaining period exceeding 5 seconds, and an average distance
of charring of not more than 35 cm
- M3: In examination in four directions, at least one sheet has a
flame-remaining period exceeding 5 seconds, and an average distance
of charring of not more than 60 cm
-
(Measurement of elongation percentage)
-
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.
Manufacturing Example 1
(Manufacture of a compound yarn of a halogen-containing flame
resistant fiber and cotton)
-
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.
Manufacturing Example 2
(Manufacture of a compound yarn of a halogen-containing flame
resistant fiber and cotton)
-
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.
Manufacturing Example 3
(Manufacture of a compound yarn of the halogen-containing flame
resistant fiber and cotton)
-
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.
Manufacturing Example 4
(Manufacture of a compound yarn of the halogen-containing flame
resistant fiber and rayon)
-
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.
Manufacturing Example 5
(Manufacture of a compound yarn of halogen-containing flame resistant
fiber and rayon)
-
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.
Manufacturing Example 6
(Manufacture of a compound yarn of halogen-containing flame resistant
fiber and rayon)
-
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.
Comparative Manufacturing Example 1
(Manufacture of a halogen-containing flame resistant fiber)
-
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
(Manufacture of union fabrics)
-
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.
Comparative Example 1
(Manufacture of union fabrics)
-
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 |
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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.
INDUSTRIAL APPLICABILITY
-
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.