EP1619278B1 - Composite en fibre ignifuge et tissu derive - Google Patents

Composite en fibre ignifuge et tissu derive Download PDF

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Publication number
EP1619278B1
EP1619278B1 EP04728234A EP04728234A EP1619278B1 EP 1619278 B1 EP1619278 B1 EP 1619278B1 EP 04728234 A EP04728234 A EP 04728234A EP 04728234 A EP04728234 A EP 04728234A EP 1619278 B1 EP1619278 B1 EP 1619278B1
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EP
European Patent Office
Prior art keywords
weight
fiber
flame resistant
flame
parts
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EP04728234A
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German (de)
English (en)
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EP1619278A1 (fr
EP1619278A4 (fr
Inventor
Wataru Mio
Susumu Iwade
Shigeru Maruyama
Hiroyasu Hagi
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Kaneka Corp
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Kaneka Corp
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Classifications

    • 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
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4282—Addition polymers
    • 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
    • D02G3/02—Yarns or threads characterised by the material or by the materials from which they are made
    • D02G3/04—Blended or other yarns or threads containing components made from different materials
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/425—Cellulose series
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4266—Natural fibres not provided for in group D04H1/425
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4282—Addition polymers
    • D04H1/43—Acrylonitrile series
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4326—Condensation or reaction polymers
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4326—Condensation or reaction polymers
    • D04H1/4334—Polyamides
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4326—Condensation or reaction polymers
    • D04H1/4334—Polyamides
    • D04H1/4342—Aromatic polyamides
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4382—Stretched reticular film fibres; Composite fibres; Mixed fibres; Ultrafine fibres; Fibres for artificial leather
    • D04H1/43835—Mixed fibres, e.g. at least two chemically different fibres or fibre blends
    • 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.]
    • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/696—Including strand or fiber material which is stated to have specific attributes [e.g., heat or fire resistance, chemical or solvent resistance, high absorption for aqueous compositions, water solubility, heat shrinkability, etc.]
    • 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.]
    • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/697—Containing at least two chemically different strand or fiber materials
    • 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.]
    • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/697—Containing at least two chemically different strand or fiber materials
    • Y10T442/698—Containing polymeric and natural strand or fiber materials

Definitions

  • the present invention relates to an inexpensive and advanced flame resistant fiber composite for furniture and beddings that can solve difficult problems for conventional flame resistant fiber composites, that is, improved flame resistance of bedding products; further improved processability and bulkiness; and satisfactory processability, touch, feeling, and sensuousness, and to a fabric produced using the flame resistant fiber composite.
  • Flame resistance is preferably given to materials used for furniture, beddings, etc. in a house for prevention of fire. Since flammable materials, such as cotton and urethane foams, are used for comfort in use of furniture or beddings, prevention of flaming to the flammable materials over a long period of time is important for fire prevention. In addition, the flame retardant materials to be used must not impair comfort or sensuousness of the furniture or beddings in use. Although various flame resistant fibers and flame retardants have so far been examined, materials fully having these advanced flame resistance and requirements for materials for furniture and beddings have not yet been realized.
  • heat-resistant fibers Although cloths obtained from the heat-resistant fibers have outstanding flame resistance, they have only poor power for preventing combustion of other non-flame resistant natural fibers and chemical fibers, and therefore materials obtained from those materials having been compounded only demonstrate inadequate flame resistance. Inevitably, there arise problems that extremely expensive materials made only from heat-resistant fibers can be used. In addition, heat-resistant fibers have problems of difficulty in production of colored patterns having high sensuousness resulting from problems of unsatisfactory processability at the time of filament opening, poor moisture absorptivity, or feeling and poor dye affinity.
  • Japanese Patent Laid-Open No. 61-89339 proposes a flame resistant fiber composite obtained by combination of an advanced flame resistant halogen containing fiber comprising flame retardants added in large quantities, and a non-flame resistant other fiber, as materials for improving the previously described disadvantages in furniture and materials for beddings, and materials having touch, outstanding moisture absorptivity, and outstanding feeling needed as general characteristics, and also having stable flame resistance. Furthermore, Japanese Patent Laid-Open No.
  • the technique can provide an advanced flame resistant fiber composite having outstanding touch and outstanding moisture absorptivity, and advanced flame resistance by means of mixing of a small amount of a heat-resistant fiber, that is, of mixing of halogen atom and Sb compounds containing fiber that can be used for work uniform usage, and cotton, etc.
  • this technique has following problems as a flame resistant fiber composite: difficulty in processing in manufacturing of nonwoven fabrics, and inadequate bulkiness in a quilting process when using as a nonwoven fabric, in order to prevent flaming to urethanes used for furniture or bedding products; problems in sensuousness caused by poor feeling of gloss and poor coloring property resulting from inclusion of fibers comprising a large quantity of added flame retardant; and inadequate fire-resistant performance for preventing flaming to cotton and urethane foams used for the above-mentioned beddings and furniture, in prolonged exposure to intense flame, while having self-extinguishing property in case of a source of fire being kept away.
  • JP 08/218 259 A disclose a flame resistant fiber composite obtained by compounding 15 to 84 parts by weight of a fiber containing 6 to 50% by weight of an 5b compound and more than 17% by weight of a polymer containing a halogen atom; 1 to 40 parts by weight of a heat-resistant fiber; 15 to 84 parts by weight of a fiber such as cellulose (cotton) or chemical fiber, based on 100 parts by weight of the fiber composite.
  • the present invention aims at improving difficult problems for conventional flame resistant fiber composites to solve, that is, flame resistance of bedding products, and at obtaining inexpensive and advanced flame resistant fiber composites used for furniture and beddings, having more improved processability and bulkiness that found in conventional products, satisfactory touch and feeling, and sensuousness.
  • a flame resistant fiber composite having outstanding sensuousness, touch, and feeling, and flame resistance of durability over prolonged flaming might be obtained using a fiber composite obtained by mixing a fiber consisting of a chlorine containing polymer, and an inflammable fiber comprising other cellulosic fibers, to a heat-resistant fiber having poor ability for preventing combustion of other inflammable fibers.
  • problems of processability or price as problems in independent use of heat-resistant fibers might also be improvable, leading to completion of the present invention.
  • the present invention relates to a flame resistant fiber composite obtained by compounding so as to give 100 % by weight of a total amount of (A) to (D): 20 to 85 % by weight of a fiber (A) containing 0.5 to 50 parts by weight of an Sb compound to 100 parts by weight of a polymer containing halogen atom of not less than 17% by weight; the polymer being a copolymer comprising: 30 to 70% by weight of acrylonitrile; 70 to 30% by weight of a halogen containing vinyl based monomer; and 0 to 10% by weight of a vinyl monomer copolymerizable therewith; 5 to 80% by weight of a fiber (B) that is a melamine fiber or a silicic acid containing cellulosic fiber ; 0 to 40 % by weight of a cellulosic fiber (C) without flame resisting treatment that is at least one selected from cotton, hemp acetate and rayon; and 0 to 40 % by weight of a synthetic fiber
  • the present invention also relates to a flame resistant fiber composite, wherein the polymer containing halogen atom of the fiber (A) is a copolymer comprising 30 to 70 % by weight of acrylonitrile, 70 to 30 % by weight of a halogen atom containing vinyl based monomer, and 0 to 10 % by weight of a vinyl monomer copolymerizable therewith;
  • the heat-resistant fiber (B) is a fiber selected from silicic acid containing cellulosic fibers, , and melamine fibers;
  • the cellulosic fiber (C) is a fiber without flame retarding treatment selected from cotton, hemp, acetate based fibers, and rayon based fibers;
  • the synthetic fiber (D) is at least one kind of fiber in polyester fibers and nylon fibers.
  • the present invention relates to a fabric and nonwoven fabric produced using the flame resistant fiber composite.
  • the fiber (A) used is a fiber containing 0.5 to 50 parts of an Sb compound to a polymer containing halogen atom of not less than 17%, and used is a fiber containing 0.5 to 5.5 parts by weight of an Sb compound to a polymer, as one example, containing chlorine atom of not less than 25% by weight.
  • a lower limit value of a halogen atom content in the polymer containing halogen atom of not less than 17% is preferably 20%, and more preferably 26%, and an upper limit value is preferably 86% more preferably 73%, and especially preferably 48%.
  • a halogen content of less than 17% disadvantageously gives difficulty in rendering the fiber flame resistant.
  • a lower limit of chlorine content in the polymer containing chlorine atom of not less than 25% by weight is preferably 26%, and an upper limit value is preferably 73 % by weight, and especially preferably 48 to 58% by weight.
  • a chlorine content of less than 25% by weight disadvantageously gives difficulty in rendering a fiber composite with inflammable fibers flame resistant.
  • the above-mentioned polymer containing halogen atom of not less than 17% includes, for example, but not limited to, polymers of monomers containing halogen; copolymers of the monomers containing halogen and monomers containing no halogen; mixtures of polymers containing halogen and polymers containing no halogen; or halogen containing polymer with halogen introduced during or after polymerization of monomers or polymers containing no halogen.
  • Examples of such a polymer containing halogen atom of not less than 17% include, for example, but not limited to: homopolymers of halogen atom containing vinyl based monomers, such as vinyl chloride, vinylidene chloride, vinyl bromide, and vinylidene bromide, or copolymers of two or more kinds thereof; copolymers of halogen atom containing vinyl based monomers and acrylonitrile, such as, acrylonitrile-vinyl chloride, acrylonitrile-vinylidene chloride, acrylonitrile-vinyl bromide, acrylonitrile-vinyl chloride-vinylidene chloride, acrylonitrile-vinyl chloride-vinyl bromide, acrylonitrile-vinylidene chloride-vinyl bromide; copolymers of one or more kinds of vinyl monomers including halogen, such as vinyl chloride, vinylidene chloride, vinyl bromide, and vinylidene
  • copolymerizable vinyl monomer examples include, for example: acrylic acid, and esters thereof; methacrylic acid, and esters thereof; acrylamide; methacryl amide; vinyl acetate; vinyl sulfonic acid, and salts thereof; methallyl sulfonic acid, and salts thereof; styrene sulfonic acid, and salts thereof; 2-acrylamide-2-methylsulfonic acid, and salts thereof. These may be used independently or two kinds or more may be used in combination.
  • the polymer containing halogen atom of not less than 17% is a polymer consisting of 30 to 70% of acrylonitrile, 70 to 30% of a halogen containing vinyl based monomer, and 0 to 10% of a vinyl monomer copolymerizable therewith, and preferably consisting of 40 to 60% of acrylonitrile, 60 to 40% of a halogen containing vinyl based monomer, and 0 to 10% of a vinyl monomer copolymerizable therewith, a fiber obtained advantageously has excellent touch as found in acrylic fibers, while having desired performances (strength, flame resistance, dye affinity, etc.).
  • the copolymerizable vinyl monomer is a sulfonic group containing vinyl monomer
  • dye affinity advantageously improves.
  • Examples of a copolymer containing units originated from the halogen containing vinyl based monomer and acrylonitrile include, for example, a copolymer consisting of 50 parts of vinyl chloride, 49 parts of acrylonitrile, and 1 part of sodium styrene sulfonate; a copolymer consisting of 43.5 parts of vinylidene chloride, 55 parts of acrylonitrile, and 1.5 parts of sodium styrene sulfonate; a copolymer consisting of 41 parts of vinylidene chloride, 56 parts of acrylonitrile, and 3 parts of sodium 2-acrylamide-2-methylsulfonate etc.
  • Sb compounds used for the present invention are used as flame retardants, and examples of the compounds include, for example, but not limited to, inorganic antimony compounds, such as, antimony oxides (Sb 2 O 3 , Sb 2 O 4 , Sb 2 O 5 , etc.), antimonic acid and salts thereof, antimony oxychloride etc. These may be used independently and may be used in combination of two or more kinds.
  • inorganic antimony compounds such as, antimony oxides (Sb 2 O 3 , Sb 2 O 4 , Sb 2 O 5 , etc.), antimonic acid and salts thereof, antimony oxychloride etc.
  • a particle diameter of the Sb compound is preferably uniformly adjusted to give not more than 2 micrometers, in order to avoid troubles, such as nozzle clogging on a process for producing a fiber obtained by adding the Sb compound to a halogen containing polymer, and to improve strength of the fiber, etc.
  • a percentage of the Sb compound to 100 parts by weight of the polymer containing halogen atom of not less than 17% by weight is 6 to 50 parts, preferably 8 to 40 parts, and more preferably 10 to 30 parts.
  • a mixing percentage, in the flame resistant fiber composite, of a fiber (A) (hereinafter referred to as fiber (A)) having the Sb compound contained in the polymer containing halogen atom of not less than 17% is necessarily increased.
  • characteristics other than the flame resistance as a flame resistant fiber composite for example, excellent performances, such as touch, moisture absorptivity, and feeling, may be hard to be obtained.
  • flame retardants usable in combination with the Sb compounds include aromatic halogenated compounds, such as hexabromobenzene; aliphatic halogenated compounds, such as chloroparaffins; halogen-containing phosphorus compounds, such as tris(2,3-dicholoropropyl) phosphate; inorganic phosphorus compounds, such as ammonium polyphosphate; inorganic magnesium compounds, such as MgO, Mg (OH) 2 , and MgCO 3 ; and inorganic tin compounds, such as stannic oxide, stannic oxy-halides, stannous hydroxide, ZnSnO 3 , and ZnSn(OH) 6 etc.
  • aromatic halogenated compounds such as hexabromobenzene
  • aliphatic halogenated compounds such as chloroparaffins
  • halogen-containing phosphorus compounds such as tris(2,3-dicholoropropyl) phosphate
  • An amount of the other flame retardants used preferably is not less than 1 part and not more than 10 parts to 100 parts by weight of the polymer containing halogen atom of not less than 17% by weight.
  • a total amount of the flame retardant is not more than 50 parts to the polymer containing halogen atom of not less than 17%, and preferably not more than 40 parts, in consideration of troubles on manufacturing process of the fiber and avoidance of physical properties impair as strength reduction of fiber etc.
  • Sb compounds used for the polymer containing chlorine atom of not less than 25% by weight in the fiber (A) is not especially limited.
  • the above-mentioned flame retardants preferable are publicly known antimony oxides (Sb 2 O 3 , Sb 2 O 4 , Sb 2 O 5 , etc.); antimonic acid and salts thereof; inorganic antimony compounds, such as antimony oxychloide; inorganic magnesium compounds, such as MgO, Mg(OH) 2 , and MgCO 3 ; and inorganic tin compounds, such as stannic oxide, stannic oxy-halides, and stannous hydroxide.
  • the compound having a particle diameter uniformly adjusted to not more than 2 micrometers is independently included, or in combination of two or more kinds thereof in an amount of 0.5 to 5.5 parts by weight.
  • the content is preferably 0.5 to 3.5 parts by weight.
  • the fiber (A) containing 0.5 to 50 parts of the Sb compound to the polymer containing halogen atom of not less than 17% may be used in either form of staple fiber, or filament, and in case of processing in compounded form with the heat-resistant fiber (B), the cellulosic fiber (C), and the inflammable fiber (D), such as chemical fiber, which are used for the present invention, fibers having similar property to fibers to be compounded are preferably selected.
  • the staple fiber preferably has a size of a fiber of 1.7 to 3.3 dtex, and a cut length of approximately 38 to 64 mm.
  • the staple fiber preferably has a size of a fiber of 7.8 dtex to 12 dtex, and a cut length of approximately 51 to 102 mm.
  • the heat-resistant fiber (B) (hereinafter referred to as fiber (B)) used for the present invention is a component is for formation of a backbone structure for maintenance of a shape of the flame resistant fiber composite in burning of the inflammable component in the flame resistant fiber composite.
  • fiber (B) has a melting point, the melting point is not less than 350 degrees C, and when it does not have a melting point, the heat-resistant fiber (B) is a fiber having heat-resisting property with a decomposition temperature of not less than 300 degrees C.
  • the fiber (B) include the fibers obtained from melamine, silicic acid containing fibers, and the fiber (B) may be used independently and two or more kinds may be used in combination.
  • the silicic acid containing cellulosic fiber used for the present invention is a component used for improvement of flame resistance and maintenance of strength of fabrics of the flame resistant fiber composite, and is a component effective for formation of carbonized films in combustion while giving outstanding comfortable properties, such as touch and moisture absorptivity.
  • the fiber is cellulose fibers containing 20 to 50% of silicic acid therein, and usually has a size of a fiber of about 1.7 to 8 dtex, and a cut length of approximately 38 to 128 mm.
  • the cellulosic fiber (C) used for the present invention (hereinafter referred to as fiber (C)) is a component for giving outstanding comfortable properties, such as touch and moisture absorptivity, to the flame resistant fiber composite of the present invention. Furthermore, the fiber (C) is a component for carbonizing, and forms carbonized materials hardly being decomposed by high temperatures in the flame resistant fiber composite, in combustion together with the polymer containing halogen atom (A).
  • Examples of the fiber (C) include fibers, such as cotton, hemp, acetate fibers, and rayon, and these may be used independently and two or more kinds may be used in combination.
  • fiber (D) examples include fibers, such as semi-synthetic fibers, such as polyester fibers, nylon fibers, and these may be used independently and two or more kinds may be used in combination. Fusible fibers, such as the polyester fibers and nylon fibers, are preferable . Polyester fibers and nylon fibers form fused materials in combustion, and the fused material covers the flame resistant fiber composite, and increases strength of the carbonized film formed from the flame resistant fiber composite. Thereby the polyester fibers and nylon fibers can advantageously attain fire-resistant performance for preventing flaming to the cotton and urethane foam to be used for beddings or furniture, also in the case where the flame resistant fiber composite is exposed to intense flame for a prolonged period of time.
  • fibers such as semi-synthetic fibers, such as polyester fibers, nylon fibers, and these may be used independently and two or more kinds may be used in combination. Fusible fibers, such as the polyester fibers and nylon fibers, are preferable . Polyester fibers and nylon fibers form fused materials in combustion,
  • polyester fibers have a high softening point and a high melting point, and improve still more preferably the heat-resisting property of the flame resistant fiber composite among them. Furthermore, polyester fibers have low cost and strong stiffness; this strong stiffness may easily give bulkiness when processed into nonwoven fabrics, resulting in excellent sensuousness when processed into quilted products. For example, the polyester fibers advantageously can give excellent looks, bulkiness, touch, etc. after finished into beds mats, bed pads, etc.
  • 100 % by weight of the flame resistant fiber composite of the present invention are produced from: 85 to 20 parts of the fiber (A) ; 15 to 80 % by weight of a silicic acid containing cellulosic fiber as the fiber (B); and 0 to 40 % by weight of the fiber (D) in case of 2 to 3 component system according to claim 8.
  • a blending ratio of the above-described fibers may be determined according to quality, such as water absorptivity, touch, moisture absorptivity, feeling, sensuousness, product strength, washing resistance, and durability, as well as flame resistance necessary for final products produced from the flame resistant fiber composite obtained.
  • the component fibers are compounded so as to give 100 % by weight of a sum total of: 85 to 20 % by weight of the fiber (A), and preferably 75 to 25 % by weight ; 15 to 80 % by weight of the silicic acid containing cellulose fiber, and preferably 20 to 70 % by weight ; and 0 to 40 % by weight of the fiber (D), and preferably 5 to 35 % by weight.
  • An amount of the fiber (A) less than 20 % by weight gives unsatisfactory flame resistance to the flame resistant fiber composite obtained.
  • an amount exceeding 80 % by weight gives outstanding flame resistance, but decreases a ratio of the silicic acid containing cellulose fiber as the fiber (B), resulting in insufficient fire-resistant performance for preventing flaming to cotton and urethane foams to be used for beddings or furniture in prolonged exposure to intense flame.
  • an amount of the fiber (D) exceeding 40 % by weight relatively decreases amounts of the fiber (A) and the fiber (B), and gives inadequate flame resistance.
  • an amount of the silicic acid containing cellulose fiber as the fiber (B) of less than 15 % by weight impairs fire-resistant performance for preventing flaming to cotton and urethane foams to be used for beddings or furniture in prolonged exposure to intense flame.
  • an amount exceeding 80 % by weight decreases a percentage of the fiber (A) to give inadequate flame resistance.
  • the silicic acid containing cellulose fiber as the fiber (B) is originally a fiber that cannot easily flame, it has poor ability for rendering other inflammable fiber flame resistant. Therefore, rendering the fiber (D) flame resistant by means of compounding of the fiber (B) and the fiber (D) will not be successful. Prominent effect may be obtained only by compounding fibers as in the present invention.
  • 100 % by weight of the flame resistant fiber composite of the present invention are produced from: 80 to 20 % by weight of the fiber (A); 5 to 40 % by weight of the fiber (B); 5 to 40 % by weight of the fiber (C); 5 to 40 % by weight of a polyester fiber as the fiber (D) in case of 4 component system according to claim 7.
  • a blending ratio of the above-mentioned fibers may be determined according to quality, such as water absorptivity, touch, moisture absorptivity, feeling, sensuousness, product strength, washing resistance, and durability, as well as flame resistance necessary for final products produced from the flame resistant fiber composite obtained.
  • the component fibers are compounded to give 100 % by weight of a sum total of: 80 to 20 % by weight of the fiber (A), and preferably 60 to 30 % by weight; 5 to 40 % by weight of the fiber (B), and preferably 10 to 35 % by weight; 5 to 40 % by weight of the fiber (C), and preferably 10 to 35 % by weight; and 5 to 40 % by weight of a polyester fiber as the fiber (D), and preferably 10 to 35 % by weight.
  • An amount of the fiber (A) less than 20 % by weight gives unsatisfactory flame resistance to the flame resistant fiber composite obtained.
  • an amount exceeding 80 % by weight gives outstanding flame resistance, but decreases a percentage of the fiber (B) and the fiber (C), resulting in insufficient fire-resistant performance for preventing flaming to cotton and urethane foams to be used for beddings or furniture in prolonged exposure to intense flame.
  • an amount of the polyester fiber as the fiber (D) of less than 5 % by weight gives unsatisfactory processability, bulkiness, touch, feeling, etc., and an amount exceeding 40 % by weight relatively decreases amounts of the fiber (A), the fiber (B), and the fiber (C), and gives inadequate flame resistance.
  • An amount of the fiber (B) of less than 5 % by weight impairs fire-resistant performance for preventing flaming to cotton and urethane foams to be used for beddings or furniture in prolonged exposure to intense flame, demonstrating inadequate improvement in flame resistant effect.
  • an mount exceeding 40 % by weight gives only flame resistant fiber composite having poor processability, touch, and sensuousness as a disadvantage of heat-resistant fibers.
  • an amount of a cellulosic fiber as the fiber (D) of less than 5 % by weight gives unsatisfactory water absorptivity, touch, dissatisfied moisture absorptivity, feeling, etc., and moreover cannot give sufficient improvement effect in flame resistance by means of carbonized film formation.
  • an mount exceeding 40 % by weight relatively decreases an amount of the fiber (A) and the fiber (B), and impairs fire-resistant performance for preventing flaming to cotton and urethane foams to be used for beddings or furniture in prolonged exposure to intense flame, resulting in inadequate flame resistance.
  • the fiber (B) is originally a fiber that cannot easily flame, it has poor ability for rendering other inflammable fiber flame resistant. Therefore, rendering the fiber (D), and the fiber (D) flame resistant by means of compounding only of the fiber (B) and fiber (D) or compounding only of the fiber (B) and the fiber (C) will not be successful. Prominent effect may be obtained only by compounding fibers as described in the present invention.
  • a blending ratio of the above-mentioned fibers may be determined according to quality, such as sensuousness, water absorptivity, touch, moisture absorptivity, feeling, product strength, washing resistance, and durability, as well as flame resistance necessary for final products produced from the flame resistant fiber composite obtained.
  • an amount of the fiber containing 0.5 to 5.5 parts by weight of the Sb compound to a polymer containing chlorine of not less than 25% by weight as the fiber (A) is preferably 40 to 80 % by weight.
  • an amount of the fiber (B) of less than 10 % by weight cannot give sufficient fire-resistant effect having durability to flame for a long time.
  • an amount exceeding 50 % by weight gives the flame resistant fiber composite with only unsatisfactory touch and sensuousness as a disadvantage of usual heat-resistant fibers.
  • An amount of the fiber (C) of less than 5 % by weight gives inadequate amount of component for forming carbonized materials, while giving unsatisfactory touch, moisture absorptivity, etc., leading to insufficient fire-resistant effect having durability to flame for a long time.
  • an amount exceeding 40 % by weight increases inflammable components in the flame resistant fiber composite, resulting in inadequate flame resistance.
  • an amount of the fiber containing 0.5 to 5.5 parts by weight of the Sb compound to a polymer containing chlorine of not less than 25% by weight as the fiber (A) is smaller than that of the fiber (C) in the flame resistant fiber composite, inadequate amount of formation of carbonized materials occurs, leading to decrease in fire-resistant effect with durability to flaming for a long time.
  • a total amount of the fiber (B) and an amount of the fiber (C) is less than 30 % by weight, an amount of components for maintaining a structure in the flame resistant fiber composite in combustion is decreased, leading to inadequate fire-resistant effect.
  • an amount exceeding 60 % by weight relatively decreases, to a total amount of the fiber (B) and amount of fiber (C), a percentage of the fiber containing 0.5 to 5.5 parts by weight the Sb compound to a polymer containing chlorine of not less than 25% by weight as the fiber (A), and does not allow sufficient formation of structures having durability to flaming for a long time.
  • the fiber (B) is a fiber that originally cannot easily flame, it has poor ability to give flame resistance to the other fiber (C), and therefore compounding of the fiber (B) with the fiber (C) may not give flame resistance to the fiber (C). And therefore, remarkable effect of rendering other fibers flame resistant will be obtained only by compounding of the fibers as described in the present invention.
  • the fiber (D) will make fused materials formed in combustion process permeate into the flame resistant fiber composite, and fill space between fibers to form a firm structure. Thereby flame resistance of the flame resistant fiber composite will be improved.
  • use of antimony oxide in the fiber containing 0.5 to 5.5 parts by weight of the Sb compound to the polymer containing chlorine of not less than 25% by weight as the fiber (A) will make chlorine compounds react with antimony oxide at high temperatures to form volatile antimony chloride, and the volatile antimony chloride will stay in the reaction system for a long time, and will work as an effective active radical scavenger because of heavier property than of air.
  • a flame resistant fiber composite of the present invention may be obtained by compounding of the above-described fiber (A), (B), (C), and (D), and may be in forms of fabrics, such as textiles, knittings, and nonwoven fabrics; assembled items of fibers, such as slivers and webs; yarn-like materials, such as spun yarns, ply yarns, twisted yarns; and string-like materials, such as knit strings and plaited cords.
  • the above-described "compounding” means a process for obtaining fabrics etc. including each fiber at predetermined ratios, by mixing of fiber (A), (B), (C), and (D) using various methods, and also means combining each fiber and yarn in stages of blending, spinning, twisting, weaving and knitting.
  • a flame resistant fiber composite of the present invention may include antistatic agents, agents for prevention of coloring by heat, light resistance improvers, whiteness improver, matting inhibitors, etc. if necessary.
  • flame resistant fiber composite of the present invention has desired flame resistance, and has characteristics excellent in touch, feeling, moisture absorptivity, sensuousness, etc.
  • a flame resistant fiber composite of the present invention may be manufactured in following methods by: spinning after blending of the fibers; manufacturing yarns and sliver and subsequent twisting thereof ; wrapping of two kinds of spun yarns around one kind of the sliver; and wrapping of one kind of the spun yarn around a sliver obtained by blending two kinds.
  • the composite may be manufactured by combination of the methods.
  • a flame resistant fiber composite of the present invention may be manufactured in following methods by: twisting of each filament; twisting of two kinds of filaments around one kind of filament, respectively; twisting of one kind of filament to a filament obtained by twisting of two kinds of filaments; and twisting of a filament obtained by twisting of two kinds of filaments to one kind of filament.
  • the composite may be manufactured by combination of the methods.
  • the composite when a part in the above-mentioned fibers (A), (B), (C), and (D) is in a form of a staple fiber, and remainder is in a form of a filament, the composite may be manufactured in a method that a component of a staple fiber is blended with other component fiber(s) to obtain a spun yarn, and the spun yarn may be twisted with other component filament(s).
  • the fabrics When a fabric is manufactured using the flame resistant fiber composite of the present invention, the fabrics has characteristics, such as outstanding flame resistance, touch, feeling, moisture absorptivity, sensuousness, etc. originated in the flame resistant fiber composite of the present invention.
  • the above-described “fabric” comprises textiles, knittings, nonwoven fabrics, and strings, and the “fabric” may be advantageously used not only in garments, such as fire-resistant work uniforms, but in interior designed products, such as curtains and carpets, beddings, such as sheets, blankets, bed mats, and bed pads etc. and moreover in applications that need general fiber characteristics and advanced flame resistance and also that need excellent touch, moisture absorptivity, feeling, and sensuousness.
  • the present invention will, hereinafter, be described in more detail, with reference to Examples, but the present invention is not limited only to the Examples.
  • the fibers were measured for flame resistance in Examples as follows in a form of a nonwoven fabric.
  • Sample nonwoven fabric with a weight of 200 g/m 2 and a dimension of 30 cm length and 45 cm width was prepared by needle punch method using a fiber mixed at a predetermined percentage.
  • Sample polyester nonwoven fabric for coverings with a weight of 200 g/m 2 and a dimension of 30 cm length and 45 cm width was prepared by needle punch method using a fiber mixed at a predetermined percentage in a same manner.
  • a simple mattress was made and was used as a sample for combustion test.
  • the sample nonwoven fabric (1) was layered on the polyester nonwoven fabric for covering (2), and a textile fabric made of a polyester (weight 120 g/m 2 ) as a surface fabric was further layered on the above-described layered fabrics to obtain a three-layered structure.
  • the three-layered structure obtained was quilted using a cotton thread, and furthermore was fixed onto a polyurethane foam (Type 360S by Toyo Tire & Rubber CO. LTD.) having a dimension with 30 cm of a length, 45 cm of a width, and 7.5 cm of a thickness, and a density of 22 kg/m 3 , using staplers.
  • the burner head has a shape of character of T, and the burner head was made by a stainless steel having an outside diameter of 1.27 cm, and a thickness of 0.0889 cm.
  • a portion of a bar of a character of T has a length of 30.48 cm, an uppermost surface for the bar part of character of T has 34 openings (perforation out of which gas comes) of 1.2 mm in a diameter at equal intervals.
  • a sample for combustion test was disposed so as to show an upper surface side of a three-layered structure.
  • the burner head was disposed in a center of the sample, and in parallel to a longitudinal direction of the sample, when observed in an upper surface of the sample, so that a face of perforation to blow out flame might give a height of 42 mm in an upper part of the sample, and that a horizontal bar of character of T might horizontally extend, and a vertical bar might extend in a vertical and upper direction.
  • combustion gas propane (99% or more of purity) was used, and conditions for gas pressure of 0.11 MPa, a gas mass flow of 12.9 L/min, and a flaming period 70 seconds were adopted.
  • Evaluation was performed by visual method, and a level where a front fabric in quilting process had voluminous touch preferable as a nonwoven fabric for beddings was evaluated as A (for example, a nonwoven fabric using polyester fibers), a level suitable for use as B, a level inferior to B was evaluated as C (for example, a nonwoven fabric using rayon fibers.)
  • sensuousness of nonwoven fabric of a flame resistant fiber composite was evaluated by sensual method. Sensuous evaluation was performed based on visual viewpoint, and a level suitable for use in usage of upholstered furniture surface fabrics, where gloss and coloring property were required, was evaluated as A, and an unsuitable level as C.
  • Sensual evaluation was performed about touch and feeling, especially feeling of dry touch, of a flame resistant fiber composite nonwoven fabric. Evaluation was performed in a manner that a preferable level or usable level in usage of a front side of upholstered furniture was evaluated as A (for example, nonwoven fabric using polyester fiber), and a level inferior to the above-mentioned level was evaluated as C (for example, nonwoven fabric using melamine fiber.)
  • A for example, nonwoven fabric using polyester fiber
  • C for example, nonwoven fabric using melamine fiber.
  • sensual evaluation was performed, respectively about feeling of gloss, and coloring property after dyeing of the sample nonwoven fabric. Sensuous evaluation was carried out from visual viewpoint. In gloss, a level suitable for use in front fabric usage of upholstered furniture was evaluated as A, and an unsuitable level was evaluated as C. In coloring property, a level suitable for use to coloring property needed in front fabric usage of upholstered furniture was evaluated as A, and an unsuitable level was evaluated as C.
  • Dyeing was performed under following conditions: cationic dyestuffs (Maxilon Yellow 2RL 0.55% omf, Maxilon Red GRL 0.25% omf, Maxilon Blue GRL 0.30% omf: all manufactured by Ciba-Geigy), acetic acid, sodium acetate, and anionic dispersant 2%omf (LevenolWX: manufactured by Kao Corp.) as an auxiliary agent, an accelerating agent 0.4% omf (sodium lauryl sulfate), liquor ratio 1 : 2.5, and boiled at normal pressure for 1-hour. After dyeing, the sample was dehydrated by a centrifugal dehydrator, and dried at ordinary temperature to obtain a nonwoven fabric having dark brown hue.
  • cationic dyestuffs Maxilon Yellow 2RL 0.55% omf, Maxilon Red GRL 0.25% omf, Maxilon Blue GRL 0.30% omf: all manufactured by Ciba-Gei
  • a copolymer comprising 51% by weight of acrylonitrile, 48% by weight of vinylidene chloride, and 1% by weight of p-sodium styrene sulfonate was dissolved so that a resin concentration might give 30% by weight into dimethylformamide.
  • Antimony trioxide 15 parts was added to 100 parts of a resin weight of the obtained resin solution to obtain a spinning solution.
  • the antimony trioxide had a particle diameter uniformly adjusted to not more than 2 micrometers, and was beforehand adjusted so that it might disperse uniformly in a diluting resin solution.
  • a spinning solution including antimony trioxide was extruded into an dimethylformamide aqueous solution with a concentration of 50% by weight, using a nozzle having a diameter of nozzle hole of 0.08 mm, and a number of holes of 300 holes.
  • the obtained fiber was dried at 120 degrees C after washing with water, subsequently, after drawing at 3 times, heat treatment was given at 145 degrees C for 5 minutes to obtain a fiber (A).
  • a chlorine content of the obtained fiber gave 35.1% by weight to a weight of a chlorine containing copolymer.
  • a staple fiber having a size of a fiber of 2.2 dtex, a strength of 2.5 cN/dtex, an elongation ratio of 40%, and a cut length of 51 mm was obtained.
  • a copolymer comprising 56% by weight of acrylonitrile, 41% by weight of vinylidene chloride, and 3% by weight of sodium 2-acrylamide-2-methylpropanesulfonate was dissolved into dimethylformamide so that a resin concentration might give 20% by weight.
  • Antimony trioxide was added into the obtained resin solution to give a spinning solution. Table 1 shows amounts of addition of antimony trioxide.
  • the antimony trioxide had a particle diameter uniformly adjusted to not more than 2 micrometers, and was beforehand adjusted so that it might disperse uniformly in a diluting resin solution.
  • a spinning solution including antimony trioxide was extruded into an dimethylformamide aqueous solution with a concentration of 50% by weight using a nozzle having a diameter of nozzle hole of 0.08 mm, and a number of holes of 300 holes.
  • the obtained fiber was dried at 120 degrees C after washing with water, and subsequently, after drawing at 3 times, heat treatment was given at 145 degrees C for 5 minutes to obtain a fiber (A).
  • a chlorine content of the obtained fiber gave 30.0% by weight to a weight of a chlorine containing copolymer.
  • a staple fiber having a size of a fiber of 2.2 dtex, strength of 2.9 cN/dtex, an elongation ratio of 38%, and a cut length of 51 mm was obtained.
  • Blended at percentages shown in Table 1 were the Fiber (A) obtained by Manufacturing Example 1; Basofil of a melamine fiber (having a distribution of a size of a fiber of approximately 1 to 3.5 dtex, and distribution of 20 to 200 mm of cut length, manufactured by Basofil Fibers), Visil as a silicon containing cellulosic fiber (1.7 dtex, 40 mm of a cut length, manufactured by SATERI INTERNATIONAL), (and Technora (1.7 dtex, 38 mm of a cut length, manufactured by Teijin Ltd.) of a para-aromatic polyamide fiber and not forming part of the invention as the fiber (B)); a rayon (1.5 dtex, 38 mm of a cut length) as the cellulosic fiber (C); and a polyester fiber (6.6 dtex, 51 mm of a cut length) as the fiber (D), and sample nonwoven fabrics were manufactured.
  • Basofil of a melamine fiber having a distribution of a size of
  • Examples 1 to 7 gave all satisfactory results in combustion test, bulkiness of sample nonwoven fabric, and characteristics (feeling etc.) as cellulosic fibers. Any kind of fiber (B) did not give difference to the results.
  • Blended at percentages shown in Table 3 were the fiber (A) obtained in Manufacturing Example 1; Visil (1.7 dtex, 40 mm of cut length, manufactured by SATERI INTERNATIONAL) of a silicic acid containing cellulose fiber as the fiber (B); and a polyester fiber (6.6 dtex, 51 mm of cut length) as the fiber (D), and sample nonwoven fabrics were manufactured. These samples were used for combustion test. Table 3 shows evaluation results.
  • Example 13 100 0 0 C C C C A C " 14 50 50 0 C C C C A C " 15 90 0 10 C C A C A A “ 16 10 0 90 A A C C A A " 17 0 100 0 C C C C A C “ 18 0 0 100 A A C C A A “ 19 0 50 50 A A C C A A " 20 35 45 20 C C C C A A A
  • Blended at percentages shown in Table 4 were the fiber (A) obtained in Manufacturing Example 2; Basofil of a melamine fiber (having a distribution of a size of a fiber of approximately 1 to 3.5 dtex, and distribution of 20 to 200 mm of cut length, manufactured by Basofil Fibers), Visil as a silicon containing cellulosic fiber (1.7 dtex, 40 mm of a cut length, manufactured by SATERI INTERNATIONAL), (and Technora (1.7 dtex, 38 mm of a cut length, manufactured by Teijin, Ltd.) as a para-aromatic polyamide fiber and not forming part of the invention as fiber (B)), ; a rayon (1.5 dtex, 38 mm of a cut length) as the cellulosic fiber (C); and a polyester fiber (6.6 dtex, 51 mm of a cut length) as the fiber (D), and sample nonwoven fabrics were manufactured.
  • Basofil of a melamine fiber having a distribution of a size
  • comparative Examples 21, 22, 23, 25, 26, 27, 29, and 31 had inadequate amounts of components for forming carbonized films, and/or since they had inadequate amounts of components for maintaining structures in the flame resistant fiber composite in combustion, they formed perforated holes and cracks in sample nonwoven fabrics during combustion test, leading to combustion of the urethane foams by direct exposure to flame of a burner.
  • Comparative Examples 32 and 33 showed satisfactory combustion test results and levels with usable touch as a surface fabric of upholstered furniture, and exhibited poor gloss due to inclusion of a large amount of antimony trioxide in the fiber (A), resulting in properties inadequate for use as a surface fabric of upholstered furniture.
  • Use of the flame resistant fiber composite of the present invention may provide fabrics having outstanding characteristics of the flame resistant fiber composite of the present invention, namely, characteristics, such as outstanding flame resistance, sensuousness, touch, feeling, moisture absorptivity.
  • the fabrics comprise textiles, knittings, nonwoven fabrics, and strings, and may preferably be used in usage requiring advanced flame resistance and general fiber characteristics, such as outstanding sensuousness, touch, moisture absorptivity, feeling, etc.
  • the usage includes furniture, such as chair coverings, beddings, pillow cases, sheets, bedcovers and mattress coverings, and furthermore surface fabrics for beddings, blankets, materials for barriers inserted between non-flame resistance fabrics and urethane foams, clothes, such as fire-resistant work uniforms, interior designed products, such as curtains and carpets etc.

Claims (16)

  1. Composite fibreux ignifuge que l'on obtient en mélangeant :
    à concurrence de 20 à 85 % en poids, une fibre (A) contenant, à concurrence de 0,5 à 50 parties en poids, un composé de Sb par rapport à 100 parties en poids d'un polymère contenant d'halogène à concurrence d'une valeur qui n'est pas inférieure à 17 % en poids, le polymère étant un copolymère comprenant : à concurrence de 30 à 70 % en poids, de l'acrylonitrile ; à concurrence de 70 à 30 % en poids, un monomère à base vinylique contenant d'halogène ; et à concurrence de 0 à 10 % en poids, un monomère vinylique copolymérisable avec lui ;
    à concurrence de 5 à 80 % en poids, une fibre thermorésistante (B), à savoir une fibre de mélamine ou une fibre cellulosique contenant de l'acide silicique ;
    à concurrence de 0 à 40 % en poids, une fibre cellulosique (C) qui n'a pas été soumise à un traitement pour la rendre ignifuge et qui représente au moins un membre choisi parmi le groupe comprenant le coton, le chanvre, l'acétate et la rayonne ; et
    à concurrence de 5 à 40 % en poids, une fibre synthétique (D) qui représente au moins un membre choisi parmi le groupe comprenant des fibres de polyester et des fibres de nylon.
  2. Composite fibreux ignifuge selon la revendication 1, que l'on obtient en mélangeant :
    à concurrence de 20 à 85 % en poids, une fibre (A) contenant, à concurrence de 6 à 50 parties en poids, un composé de Sb par rapport à 100 parties en poids du polymère contenant d'halogène à concurrence d'une valeur qui n'est pas inférieure à 17 % en poids ;
    à concurrence de 15 à 80 % en poids, la fibre thermorésistante (B) ; et
    à concurrence de 0 à 40 % en poids, la fibre synthétique (D).
  3. Composite fibreux ignifuge selon la revendication 1, que l'on obtient en mélangeant :
    à concurrence de 20 à 85 % en poids, une fibre (A) contenant, à concurrence de 0,5 à 50 parties en poids, un composé de Sb par rapport à 100 parties en poids d'un polymère contenant d'halogène à concurrence d'une valeur qui n'est pas inférieure à 17 % en poids ;
    à concurrence de 5 à 40 % en poids, la fibre thermorésistante (B) ;
    à concurrence de 5 à 40 % en poids, la fibre cellulosique (C) ; et
    à concurrence de 5 à 40 % en poids, la fibre synthétique (D).
  4. Composite fibreux ignifuge selon la revendication 2, que l'on obtient en mélangeant :
    à concurrence de 85 à 20 % en poids, une fibre contenant, à concurrence de 6 à 50 parties en poids, un composé de Sb par rapport à 100 parties en poids d'un polymère contenant un atome de chlore à concurrence d'une valeur qui n'est pas inférieure à 17 % en poids, à titre de polymère contenant d'halogène ;
    à concurrence de 15 à 80 % en poids, une fibre cellulosique contenant de l'acide silicique à titre de fibre thermorésistante (B) ; et
    à concurrence de 0 à 40 % en poids, un ou plusieurs types de fibre synthétique (D),
    le composite fibreux ignifuge étant mélangé de façon à obtenir les teneurs suivantes pour chaque fibre : (A) >= (D) ou (B) >= (D).
  5. Composite fibreux ignifuge selon la revendication 1, 2, 3 ou 4, comprenant, à concurrence de 5 à 35 % ; des fibres de polyester et/ou des fibres de nylon, à titre de fibre synthétique (D) dans le composite fibreux ignifuge.
  6. Composite fibreux ignifuge selon la revendication 1, 2, 4 ou 5, dans lequel une fibre cellulosique contenant de l'acide silicique, à titre de fibre thermorésistante (B), contient de l'acide silicique à concurrence de 20 à 50 % en poids.
  7. Composite fibreux ignifuge selon la revendication 1 ou 3, que l'on obtient en mélangeant :
    à concurrence de 80 à 20 % en poids, une fibre (A) contenant, à concurrence de 6 à 50 parties en poids, un composé de Sb par rapport à 100 parties en poids d'un polymère contenant un atome de chlore à concurrence d'une valeur qui n'est pas inférieure à 17 % en poids, à titre de polymère contenant d'halogène ;
    à concurrence de 5 à 40 % en poids, la fibre thermorésistante (B) ;
    à concurrence de 5 à 40 % en poids, la fibre cellulosique (C) ; et
    à concurrence de 5 à 40 % en poids, une fibre de polyester à titre de fibre synthétique (D).
  8. Composite fibreux ignifuge selon la revendication 1, comprenant :
    à concurrence de 30 à 70 % en poids, une fibre contenant, à concurrence de 0,5 à 5,5 parties en poids, un composé de Sb par rapport à 100 parties en poids d'un polymère contenant un atome de chlore à concurrence d'une valeur qui n'est pas inférieure à 25 % en poids, à titre de polymère contenant d'halogène, à titre de fibre (A) ;
    à concurrence de 10 à 50 % en poids, la fibre thermorésistante (B) ;
    à concurrence de 5 à 40 % en poids, la fibre cellulosique (C) ; et
    à concurrence de 0 à 30 % en poids, la fibre synthétique (D), les teneurs des fibres (A) à (D) satisfaisant aux équation
    (1) (A) >= (D) ;
    (2) (A) + (D) représentent de 50 à 90 % en poids ; et
    (3) (C) + (D) représentent de 30 à 60 % en poids.
  9. Composite fibreux ignifuge selon la revendication 1 ou 8, dans lequel un polymère contenant du chlore, à titre de polymère contenant d'halogène, représente un copolymère comprenant .
    à concurrence de 40 à 60 % en poids, de l'acrylonitrile ;
    à concurrence de 60 à 40 % en poids, un monomère vinylique contenant du chlore ; et
    à concurrence de 0 à 10 % en poids, un monomère vinylique copolymérisables avec lui.
  10. Composite fibreux ignifuge selon la revendication 1 à 3, 8 ou 9, dans lequel la fibre synthétique (D) comprend, à concurrence de 16 à 100 % en poids, au moins un type de fibre comprenant des fibres de polyester et des fibres de nylon.
  11. Composite fibreux ignifuge selon la revendication 1 à 3, 8, 9 ou 10, dans lequel la fibre synthétique (D) représente une fibre synthétique comprenant, à concurrence de 16 à 100 % en poids, une fibre de polyester.
  12. Composite fibreux ignifuge selon la revendication 1, 8, 9, 10 ou 11, dans lequel une fibre contenant un composé de Sb dans un polymère à titre de polymère contenant d'halogène, contenant un atome de chlore, est présente en une quantité de 40 à 70 % en poids.
  13. Composite fibreux ignifuge selon la revendication 1, 8, 9, 10, 11 ou 12, dans lequel la fibre cellulosique (C) est présente en une quantité de 30 à 40 % en poids.
  14. Composite fibreux ignifuge selon la revendication 1, 8, 9, 10, 11, 12 ou 13, dans lequel la teneur en composé de Sb s'élève de 0,5 à 3,5 parties en poids par rapport à 100 parties en poids du polymère contenant un atome de chlore à titre de polymère contenant d'halogène.
  15. Tissu confectionné en utilisant le composite fibreux ignifuge selon les revendications 1 à 14.
  16. Étoffe non-tissée confectionnée en utilisant le composite fibreux ignifuge selon les revendications 1 à 14.
EP04728234A 2003-04-28 2004-04-19 Composite en fibre ignifuge et tissu derive Expired - Lifetime EP1619278B1 (fr)

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JP2003123269 2003-04-28
JP2003125161 2003-04-30
JP2003125162 2003-04-30
PCT/JP2004/005583 WO2004097088A1 (fr) 2003-04-28 2004-04-19 Composite en fibre ignifuge et tissu derive

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EP1619278A1 EP1619278A1 (fr) 2006-01-25
EP1619278A4 EP1619278A4 (fr) 2006-09-20
EP1619278B1 true EP1619278B1 (fr) 2009-06-10

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EP (1) EP1619278B1 (fr)
JP (1) JP4308820B2 (fr)
KR (1) KR20060007032A (fr)
CN (1) CN1806071B (fr)
AT (1) ATE433509T1 (fr)
CA (1) CA2523378A1 (fr)
DE (1) DE602004021484D1 (fr)
ES (1) ES2326170T3 (fr)
MX (1) MXPA05011334A (fr)
WO (1) WO2004097088A1 (fr)

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ES2326170T3 (es) 2009-10-02
ATE433509T1 (de) 2009-06-15
CN1806071B (zh) 2011-08-31
JPWO2004097088A1 (ja) 2006-07-13
KR20060007032A (ko) 2006-01-23
EP1619278A1 (fr) 2006-01-25
WO2004097088A1 (fr) 2004-11-11
US20060234592A1 (en) 2006-10-19
DE602004021484D1 (de) 2009-07-23
JP4308820B2 (ja) 2009-08-05
EP1619278A4 (fr) 2006-09-20
MXPA05011334A (es) 2006-01-30
CA2523378A1 (fr) 2004-11-11
CN1806071A (zh) 2006-07-19

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