EP3109351A1 - Mehrschichtiges gesponnenes garn, damit hergestelltes hitzebeständiges gewebe und hitzebeständige schutzkleidung - Google Patents

Mehrschichtiges gesponnenes garn, damit hergestelltes hitzebeständiges gewebe und hitzebeständige schutzkleidung Download PDF

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Publication number
EP3109351A1
EP3109351A1 EP16745032.9A EP16745032A EP3109351A1 EP 3109351 A1 EP3109351 A1 EP 3109351A1 EP 16745032 A EP16745032 A EP 16745032A EP 3109351 A1 EP3109351 A1 EP 3109351A1
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EP
European Patent Office
Prior art keywords
fiber
spun yarn
heat
flame
multilayer
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EP16745032.9A
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English (en)
French (fr)
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EP3109351A4 (de
Inventor
Hideki Omori
Masanobu Takahashi
Takayuki Okabe
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Japan Wool Textile Co Ltd
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Japan Wool Textile Co Ltd
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Publication of EP3109351A1 publication Critical patent/EP3109351A1/de
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    • 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
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2331/00—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products
    • D10B2331/02—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products polyamides
    • D10B2331/021—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products polyamides aromatic polyamides, e.g. aramides
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2331/00—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products
    • D10B2331/14—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products polycondensates of cyclic compounds, e.g. polyimides, polybenzimidazoles
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2401/00—Physical properties
    • D10B2401/14—Dyeability

Definitions

  • the present invention relates to a multilayer-structured spun yarn including a polybenzimidazole fiber and a para-aramid fiber, and a heat-resistant textile and a heat-resistant protective suit that use the multilayer-structured spun yarn.
  • a polybenzimidazole fiber which has excellent heat resistance and flame retardance, has been used for a firefighter suit in the U.S., Canada, Australia and some countries in Europe.
  • dtex decitex
  • a woven fabric woven with the polybenzimidazole fiber and a para-aramid fiber is usually used.
  • either one of warp or weft is a spun yarn composed of the polybenzimidazole fiber, and the other is a filament yarn composed of the para-aramid fiber.
  • the present inventors have proposed a sheath-core spun yarn including a core of a stretch-broken spun yarn of a para-aramid fiber and a sheath of a meta-aramid fiber, a flame-retardant acrylic fiber, a polyetherimide fiber or the like (Patent Documents 1-2).
  • the polybenzimidazole fiber Since the polybenzimidazole fiber is not dyeable and only fibers spun-dyed with limited range of colors are available, it is difficult to obtain fibers and textiles with a variety of colors.
  • the conventional woven fabric that is woven with a spun yarn composed of the polybenzimidazole fiber and a filament yarn composed of the para-aramid fiber, the para-aramid fiber will be fibrillated easily due to abrasion or the like at the time of washing and wearing. This causes a whitening phenomenon on the textile surface, resulting in significantly poor appearance.
  • the para-aramid fiber undergoes color change by light, and tends to lose strength. The heat resistance and flame retardance are still insufficient in the fiber compositions proposed in Patent Documents 1 and 2.
  • the present invention provides a multilayer-structured spun yarn that can facilitate color matching, prevent damage to the appearance due to fibrillation and prevent embrittlement by light, and can also achieve high heat resistance and flame retardance, and a heat-resistant textile and a heat-resistant protective suit that use the multilayer-structured spun yarn.
  • a multilayer-structured spun yarn of the present invention includes a core component including a stretch-broken spun yarn of a para-aramid fiber and a sheath component including a polybenzimidazole fiber.
  • the sheath component includes the polybenzimidazole fiber and a flame-retardant fiber (however, excluding the para-aramid fiber and the polybenzimidazole fiber), which are blended together, the polybenzimidazole fiber and the flame-retardant fiber have at least two different colors, and the multilayer-structured spun yarn appears to be different in color tone from the polybenzimidazole fiber and the flame-retardant fiber.
  • a heat-resistant textile of the present invention is characterized by the use of the multilayer-structured spun yarn.
  • a heat-resistant protective suit of the present invention is characterized by the use of the heat-resistant textile.
  • a multilayer-structured spun yarn of the present invention includes a core component including a stretch-broken spun yarn of a para-aramid fiber and a sheath component including a polybenzimidazole fiber.
  • the sheath component includes the polybenzimidazole fiber and a flame-retardant fiber (however, excluding the para-aramid fiber and the polybenzimidazole fiber), which are blended together, the polybenzimidazole fiber and the flame-retardant fiber have at least two different colors, and the multilayer-structured spun yarn appears to be different in color tone from the polybenzimidazole fiber and the flame-retardant fiber.
  • the present invention can provide the multilayer-structured spun yarn that can facilitate color matching, can improve the washing resistance in terms of preventing damage to the appearance due to fibrillation, and can also achieve high heat resistance and high flame retardance, and the heat-resistant textile and the heat-resistant protective suit that use the multilayer-structured spun yarn.
  • the polybenzimidazole fiber has high moisture content and a large total heat loss, which enables heat generated by the body of a user to move largely, thereby providing a comfortable heat-resistant protective suit.
  • a multilayer-structured spun yarn of the present invention includes a core component and a sheath component.
  • the core component includes a stretch-broken para-aramid fiber.
  • the sheath component includes a polybenzimidazole fiber and a flame-retardant fiber (however, excluding the para-aramid fiber and the polybenzimidazole fiber), which are blended together.
  • the polybenzimidazole fiber (hereinafter, referred also to as "PBI fiber”) is a fiber made of, e.g., a polymer of 2,2'-(m-phenylen)-5,5'-bibenzimidazole and has a thermal decomposition temperature of more than 600°C, a deflection temperature under load of 410°C, a glass transition temperature of 427°C, and an oxygen index (OI) of 41 or more.
  • PBI fiber is a fiber made of, e.g., a polymer of 2,2'-(m-phenylen)-5,5'-bibenzimidazole and has a thermal decomposition temperature of more than 600°C, a deflection temperature under load of 410°C, a glass transition temperature of 427°C, and an oxygen index (OI) of 41 or more.
  • the PBI fiber can maintain a strength retention of 95% even when exposed to the air at 230°C for two weeks, and can maintain fiber properties to a temperature of 1000°C in nitrogen, and inherently has both incombustibility and high heat resistance (above is cited from " Encyclopedia of fiber” page 848, Maruzen, March 25, 2002 ).
  • PBI fiber products manufactured by PBI Performance Products, Inc. in the US are known.
  • the PBI fiber has a high equilibrium moisture regain of about 14.6 mass%, which allows a textile including the PBI fiber to have a total heat loss of 300 W/m 2 or more measured in accordance with ASTM F 1868 Part C, and enables heat generated by the body of a user to move largely, thereby providing a comfortable heat-resistant protective suit.
  • para-aramid fiber examples include, as homopolymer-based para-aramid fibers, "Kevlar” (trade name) manufactured by DuPont in the U.S. (the same trade name is used for the product of Du Pont-Toray Co., Ltd. in Japan) and “Twaron” (trade name) manufactured by Teijin, Ltd., and as copolymer-based para-aramid fibers, "Technora” (trade name) manufactured by Teijin, Ltd. These fibers have a tensile strength of 20.3 to 24.7 cN/dtex, a thermal decomposition starting temperature of about 500°C, and an oxygen index (OI) of in a range of 25 to 29.
  • the heat resistance and flame retardance of the para-aramid fiber are inferior to those of the PBI fiber, but are higher than those of the ordinary fibers.
  • the sheath component includes the PBI fiber and a flame-retardant fiber (however, excluding the para-aramid fiber and the PBI fiber), which are blended together.
  • the PBI fiber and the flame-retardant fiber have at least two different colors, and the multilayer-structured spun yarn appears to be different in color tone from the PBI fiber and the flame-retardant fiber. Color mixing can be achieved by blending the respective fibers to produce a predetermined color tone, so that color matching is facilitated.
  • the PBI fiber is preferably an unbleached fiber or spun-dyed fiber.
  • unbleached indicates a fiber state of being neither spun-dyed nor dyed.
  • the PBI fiber is yellow in the unbleached state. This yellow color is used as it is for color mixing.
  • Spin-dyeing indicates coloring a polymer by adding a coloring agent and forming the polymer into a fiber. Accordingly, the color tone of the spun-dyed fiber is limited.
  • the three stages for imparting color phases to a dyeable fiber are described as follows.
  • Cotton stage this stage includes loose stock-dyeing to directly dye fiber masses in a separate state; sliver-dyeing to dye a staple bundle, i.e., a fiber bundle in a sliver state; and top-dyeing to wind up a staple bundle to make a top and dye the top.
  • Yarn stage yarn-dyeing means to dye a fiber in a yarn state, and this stage includes, depending on the form of dyeing; hank (skein)-dyeing and cone-dyeing to wind up a fiber bundle softly on a specific dye cone tube for allowing a dyeing liquid to permeate easily, and dye the fibers.
  • Knitted or woven fabric stage this stage includes fabric-dyeing to dye a textile in a cloth state.
  • This stage (3) is called after-dyeing because dyeing is performed after knitting or weaving of yarns into a fabric.
  • the stage (1) and stage (2) in which fibers or yarns are dyed before knitting or weaving, are colored yarns and dyed yarns respectively.
  • the stages (1) and (2) are also called fiber-dyeing.
  • the flame-retardant fiber of the multilayer-structured spun yarn is preferably at least one selected from a spun-dyed fiber, a loose stock-dyed fiber, a sliver dyed fiber, a top dyed fiber, and yarn-dyed fiber.
  • the flame-retardant fiber after made into a textile may be piece-dyed. By doing so, it is possible to develop a desired color tone by using the flame-retardant fibers with a variety of color tones and by blending or dyeing them, despite that the PBI fiber is unbleached or spun-dyed and is limited in color tone.
  • the content of the PBI fiber is 10 mass% or more and 90 mass% or less, and the content of the flame-retardant fiber is 10 mass% or more and 90 mass% or less when the amount of the sheath component is 100 mass%. More preferably, the content of the PBI fiber is 20 mass% or more and 80 mass% or less, and the content of the flame-retardant fiber is 20 mass% or more and 80 mass% or less, and further preferably the content of the PBI fiber is 30 mass% or more and 70 mass% or less, and the content of the flame-retardant fiber is 30 mass% or more and 70 mass% or less when the amount of the sheath component is 100 mass%.
  • the contents are in the above ranges, color matching is facilitated and high heat resistance is achieved.
  • the content of the core component is 20 to 40 mass% and the content of the sheath component is 60 to 80 mass%, and more preferably, the content of the core component is 22 to 35 mass% and the content of the sheath component is 65 to 78 mass% when the amount of the multilayer-structured spun yarn is 100 mass%.
  • the content of the core component is less than 20 mass%, a stretch-broken yarn of the core component should have a very small diameter, and makes it difficult to produce the stretch-broken yarn.
  • the content of the core component is more than 40 mass%, coatability of the sheath fiber deteriorates.
  • the content of the sheath component is less than 60 mass%, coatability is not favorable and when the content of the sheath component is more than 80 mass%, the fineness of the multilayer-structured spun yarn as a whole increases, and it is not preferred.
  • the PBI fiber is preferably a stretch-broken fiber obtained by breaking a tow, a bias-cut fiber, or a square-cut fiber.
  • the stretch-broken fiber is a fiber closely similar to the stretch-broken spun yarn of a para-aramid fiber of the core component (as both fibers are tear-off fibers), and provides excellent affinity between the core component and the sheath component, thereby achieving a multilayer structured spun yarn having excellent conformity.
  • the sheath component may be bias-cut or square-cut. To bias-cut means to cut a filament bundle (tow) perpendicularly and diagonally to the yarn advancing direction alternately and repeatedly.
  • a bias-cut fiber with a fiber length of 76/102 mm the fiber lengths are distributed uniformly from a minimal length of 76 mm to a maximum length of 102 mm.
  • square-cut means to cut a filament bundle (tow) perpendicularly with a fixed fiber length.
  • all fiber lengths are distributed uniformly in 51mm.
  • the fiber length of the cut-fiber is preferably in a range of 30 to 180 mm, more preferably in a range of 45 to 150 mm, and particularly preferably in a range of 50 to 125 mm. With these ranges, the strength can be maintained even higher.
  • the single yarn fineness of the cut-fiber is preferably in a range of 1 to 5 dtex, and more preferably in a range of 1.5 to 4 dtex.
  • the flame-retardant fiber has an oxygen index (OI) of 26 or more measured in accordance with JIS K 7201-2.
  • OI oxygen index
  • both of the stretch-broken para-aramid fiber of the core component and the PBI fiber of the sheath component can provide a multilayer-structured spun yarn having high heat resistance and high flame retardance.
  • the flame-retardant fiber is preferably at least one fiber selected from a meta-aramid fiber, a polyalylate fiber, a polybenzoxazole fiber, a polyetherimide fiber, a flame-retardant wool, a flame-retardant rayon, a flame-retardant cotton, and a flame-retardant acrylic fiber.
  • the sheath component fiber is processed into a staple bundle for a sheath fiber having an optimal shape and configuration.
  • French system worsted spinning is a suitable method for wool having a large fineness and a long fiber length.
  • fiber bundles slivers
  • this method is referred to as "sliver blending".
  • This method provides a high yield and is suitable for manufacturing a wide range of products in small quantities.
  • cotton spinning is a suitable method for cotton having a small yarn fineness and a short fiber length.
  • the fibers are mixed mainly by a carding machine in a mixing and blowing process and a carding process.
  • this method is referred to as "carding blending”.
  • This method provides a poor yield but is suitable for manufacturing a small kind of products in large quantities.
  • an antistatic fiber further is blended with the sheath fiber.
  • the antistatic fiber is blended preferably in a range of 0.1 to 1 mass%.
  • the multilayer-structured spun yarn has a metric count preferably in a range of 28 to 52 (fineness: 357 to 192 dtex). When the metric count is in this range, a protective suit having an excellent workability can be obtained.
  • the multilayer-structured spun yarn is used to make a heat-resistant textile.
  • the heat-resistant textile is preferably a woven fabric.
  • the heat-resistant textile shows that a flame does not reach side edges, no hole is formed, no molten debris is produced, an average afterflame time is 2 seconds or less, and an average afterglow time is 2 second or less.
  • the heat-resistant textile is preferably free from melting, dripping, separation and firing, and has a shrinkage rate of 5% or less in a heat resistance test in accordance with ISO 11613-1999 at 180°C for 5 minutes. The above physical properties can provide a textile having heat resistance and flame retardance at an excellent level.
  • the heat-resistant textile has an oxygen index (OI) of 26 or more, more preferably 26 to 50, still more preferably 32 to 50, and particularly preferably 37 to 48 measured in accordance with JIS K 7201-2. With these ranges, the flame retardance can be improved further.
  • OI oxygen index
  • the heat-resistant textile is washed 5 times in a washing test in accordance with ISO 6330-1984, 2A-E specified in ISO 11613-1999 as the international performance standards, which is intended to measure washing resistance in terms of preventing damage to the appearance of the fabric due to fibrillation, the heat-resistant textile is free from a whitening phenomenon. With this characteristic, the product value can be maintained higher. It is preferable that the light resistance of the heat-resistant textile is grade 2 to 3 in both a carbon arc light irradiation test according to JIS L 0842.7.2 (a) and a xenon arc light irradiation test according to JIS L 0843. With this characteristic, color change by light can be reduced and the product value can be maintained higher.
  • the heat-resistant protective suit that uses the heat-resistant textile of the present invention is suitable for a fire fighter suit, and work clothing worn by ambulance crews, rescue workers, maritime lifeguards, military, workers at oil-related facilities, and workers at chemical facilities.
  • the outer layer of the suit is preferably provided with the heat-resistant textile of the present invention, because it has high heat resistance.
  • flame-retardant fibers to be blended in the sheath component are described below.
  • meta-aramid fibers examples include "Nomex” (trade name) manufactured by DuPont in the US (the same trade name for meta-aramid fiber manufactured by DuPont-Toray Co., Ltd in Japan) and “Conex” (trade name) manufactured by Teijin, Ltd.
  • the meta-aramid fibers has an oxygen index (OI) of 29 to 30.
  • the flame-retardant wool commonly-used merino wool or the like treated with a Zirpro process, which is a process with titanium and zirconium salt is available.
  • the wool may be either unmodified wool or wool that has been modified by removing the surface scales for shrink proofing. Such unmodified or modified wool is used to improve hygroscopicity and to shield a radiant heat so that the comfort in wearing is kept preferable despite wetting from sweat during exertion under a high-temperature and severe environment, thereby exhibiting heat resistance for protecting the human body.
  • the flame-retardant wool has an oxygen index (OI) of 27 to 33.
  • Examples of the flame-retardant rayon include a rayon treated with a Proban process (an ammonium curing process using tetrakis (hydroxymethyl) phosphonium chloride developed by Albright & Wilson Ltd.), a rayon treated with a Pyrovatex CP process (process with N-methylol dimethylphosphonopropionamide) developed by Ciba-Geigy, and "Viscose FR" (trade name) manufactured by Lenzing AG in Austria.
  • the flame-retardant rayon has an oxygen index (OI) of 26.
  • a cotton treated with a Proban process in which tetrakis (hydroxyethyl) phosphonium chloride was applied to the cotton by ammonia curing
  • a cotton treated with a Pyrovatex CP process process with N-methylol dimethylphosphonopropionamide, or the like
  • the flame-retardant cotton has an oxygen index (OI) of 26.
  • the flame-retardant acrylic fiber an acrylic fiber obtained by copolymerizing an acrylonitrile with a vinyl chloride-based monomer as a flame retarder, and "PROTEX” (trade name) manufactured by Kaneka Corporation, or the like can be used.
  • the flame-retardant acrylic fiber has an oxygen index (OI) of 29 to 37.
  • polyetherimide (PEI) fiber is "Ultem” (trade name) manufactured by Sabic Innovative Plastics (oxygen index (OI): 32). This fiber has a tensile strength of about 3 cN/dtex. It is preferable that the polyetherimide single fiber has a fineness of 3.9 dtex (3.5 deniers) or less and more preferably 2.8 dtex (2.5 deniers) or less. When the fineness is 3.9 dtex (3.5 deniers) or less, the fiber has flexibility and preferable feeling, and it can be applied suitably to work clothing.
  • a preferable average fiber length of the polyetherimide fiber is in a range of 30 to 180 mm, and more preferably in a range of 45 to 150 mm, and particularly preferably in a range of 50 to 125 mm.
  • the polyetherimide fiber having the fiber length in this range can be spun easily.
  • polyalylate fiber is "VECTRAN” (trade name) manufactured by KURARAY CO., LTD. This fiber has a strength of 18 to 22 cN/dtex, an elastic modulus of 600 to 741 cN/dtex, a melting point or decomposition temperature of 300°C, and an oxygen index (OI) of 27 to 28.
  • PBO fiber polybenzoxazole (PBO) fiber
  • ZYLON trade name
  • This fiber has a tensile strength of 37 cN/dtex, an elastic modulus of 270 MPa, a melting point or decomposition temperature of 670°C, and an oxygen index (OI) of 64.
  • a stretch-broken spun yarn is used for the core component.
  • the core component is a stretch-broken spun yarn of a para-aramid fiber.
  • the stretch-broken spun yarn indicates a yarn prepared by drafting and cutting (tearing off) a filament bundle (tow), and twisting.
  • the spinning may be a direct spinning to perform drafting and twisting at a single frame.
  • the spinning may be a Perlok spinning or a converter spinning, in which the fiber is once made as a sliver and twisted to make a spun yarn in two or more steps.
  • the direct spinning is preferred.
  • the preferred fineness of the stretch-broken spun yarn is in a range of 5.56 to 20.0 tex (metric count: 50 to 180), and more preferably, in a range of 6.67 to 16.7 tex (metric count: 60 to 150).
  • the stretch-broken spun yarn having a fineness in the above- ranges has a high strength and can be applied suitably to heat-resistant protective suit and the like in light of its feeling and the like.
  • the twist number is 350 to 550 time/m or more preferably 400 to 500 time/m for a single yarn having a metric count of 125. When the twist number is in this range, conformity with the sheath fiber is improved further.
  • the preferred fiber lengths are distributed in the range of 30 to 180 mm, the average fiber length is in a range of 45 to 150 mm and preferably in a range of 50 to 125 mm. With these ranges, the strength can be maintained even higher.
  • FIG. 1 is a perspective view showing main elements of a ring frame in an example of the present invention.
  • a pair of columns 2, 3 different from each other in diameter are provided on a front-bottom roller 1 that is driven to rotate positively.
  • the columns 2, 3 are linked directly and coaxially in the axial direction.
  • a pair of cylindrical front-top rollers 4, 5 different from each other in diameter are placed on the columns 2, 3, a pair of cylindrical front-top rollers 4, 5 different from each other in diameter are placed.
  • the difference in diameter between the front-top rollers 4, 5 is substantially the same as the difference in diameter between the columns 2, 3 below, but the dimensional relationship is reverse to that of the columns 2, 3 below.
  • the front-top rollers 4, 5 are covered with rubber cots, and fit respectively on a loaded common arbor 6 so as to roll independently.
  • a staple bundle 16 drawn out from a rove bobbin is fed from a guide bar to a back roller 8 through a trumpet feeder 7.
  • the staple bundle 15 is prepared as a para-aramid stretch-broken fiber bundle for making a core fiber, while the staple bundle 16 is prepared as a sheath fiber bungle.
  • the trumpet feeder 7 can be swung in the axial direction of the front-bottom roller 1, and the swing width can be adjusted.
  • a staple bundle B that has been delivered from the back roller 8 and passed through the draft apron 9 is spun out in a state being held by the large-diameter column 3 and the small-diameter cylindrical front-top roller 5.
  • a staple bundle A is fed through the yarn guide 14 to the small-diameter column 2 and the large-diameter cylindrical front-top roller 4, and then spun out.
  • the delivery speed of the staple bundle 16 spun out from the large-diameter column 3 is greater than the spinning speed of the staple bundle 15 spun out from the small-diameter column 2. Therefore, when the two spun staple bundles 15, 16 are twisted through a snail wire 10, the staple bundle 16 is entangled around the staple bundle 15, thereby a sheath-core type multilayer-structured spun yarn 17 is formed, with the staple bundle 15 as the core and the staple bundle 16 as the sheath.
  • the overfeeding rate of the staple bundle 16 to the staple bundle 15 is 5 to 9%, and more preferably 6 to 8%.
  • the staple bundle 16 can wrap up the staple bundle 15 at a substantially 100% cover rate.
  • the produced multilayer-structured spun yarn 17 is wound up by a yarn pipe 13 on the draft part through an anti-node ring 11 and a traveler 12. Even when there is a variation in the positions to hold the staple bundles 15, 16 on the columns 2, 3 depending on the draft parts, since the delivery speed ratio between them is always constant, there is no possibility that the property of the produced sheath-core type multilayer-structured spun yarn 17 varies depending on the draft parts. Further, when the trumpet feeder 7 is swung in a possible range in the axial direction of the front-bottom roller 1, the frictional region of the rubber cot cover of the front-top roller 5 to be rubbed against the staple bundle 16 is dispersed to prevent early abrasion of the rubber cot cover. Though not shown, it is preferable that the yarn guide 14 is swung in the axial direction of the front-bottom roller 1 so as to decrease the abrasion of the rubber cot cover on the cylindrical front-top roller 4.
  • a preferred twist direction for a single yarn of a sheath-core type multilayer-structured spun yarn is the same as that of a single yarn of a stretch-broken yarn, and, the most preferred twist number T max (time/m) is decided by the fineness So (tex) and the twist number To (time/m) of the stretch-broken spun yarn irrespective of the single yarn fineness after covering with the sheath fiber, and thus the following equation is established.
  • T max R s • T 0 • S 0
  • the most preferred twist number T max (time/m) is decided by the count C 0 (m/g) and the twist number To (time/m) of the single yarn of the stretch-broken spun yarn, and thus the following equation is established.
  • T max R c • T 0 / C 0
  • a core component fiber 21 is a stretch-broken spun yarn of a para-aramid fiber
  • a sheath component fiber 22 includes the PBI fiber and the meta-aramid fiber, which covers around the core component 21 and has an excellent conformity. Therefore, damage caused by abrasion or the like in the para-aramid fiber at the time of washing can be reduced and/or the percentage of the para-aramid fiber exposed on the spun yarn surface is lowered, and thus the appearance will not deteriorate even when damage caused by abrasion or the like occurs due to wearing and washing. Similarly, color change and decrease in the strength are less likely to occur. In any way degradation in the quality can be prevented.
  • a protective suit textile of the present invention is preferably a woven fabric formed of a two-fold yarn prepared by twisting two yarns of the sheath-core spun yarn (single yarn).
  • a two-fold yarn is used since the two-fold yarn has at least a doubled strength when compared to a single yarn and thereby can provide a conjugative power to prevent yarn breakage during weaving, and irregularity in thickness of the single yarn is compensated to provide a delicate mesh texture to the woven fabric.
  • the two-fold yarn is produced by use of a twister such as a double-twister. As the name itself suggests, the double-twister has a remarkable productivity because it can produce two twists at a single rotation of a spindle.
  • the double-twister has 6 abrasion points on its extremely long yarn path and thus, a covered portion of the fiber can be peeled and scratched, and the core portion of the fiber tends to be exposed.
  • a ring twister having two abrasion points is preferable, and an up-twister having two abrasion points and an extremely short twisting eyelet is more preferable.
  • a sized single yarn is used for the warps.
  • the adjacent warps rub each other repeatedly at every shedding motion of the loom, and rotate in a direction to reversely twist every time tensile force is applied.
  • the surface fuzzes of the warps get entangled.
  • further fuzzes are drawn out from the yarns so as to degrade the conjunctive power.
  • the yarn will be broken to stop the loom. If the fiber is hydrophilic, starches or the like easily adhere to the yarn.
  • the conjugative power will not deteriorate during the weaving, and no breakage of the warps occurs. Furthermore, the thus woven fabric later can be desized easily by washing with water during a refining step.
  • Warp breakage in a loom depends considerably on the conjugative power regarding the rubbing, entanglement and peeling of the surface fuzzes rather than the strength (cN/dtex) of the single fiber that forms the yarn. Therefore, it is preferable that warps of these fibers are prepared as two-fold yarns.
  • the twist direction (S-twist or Z-twist) and the twist factor K 2 of a two-fold yarn with respect to the twist direction and the twist factor K 1 of a single yarn are set depending on the type of the fabric to be woven.
  • a wool woven fabric will be explained as an example.
  • the two-fold yarn is also Z-twisted and K 2 is set to be larger so as to make a so-called high twisted yarn.
  • the surface of the woven fabric is napped sufficiently to provide softness, bulkiness and shiny smoothness.
  • the single yarn is Z-twisted, while the two-fold yarn is S-twisted and its K 2 is set smaller in order to make a so-called loose twisted yarn, thereby promoting felting and raising.
  • the count is in a range of 1/28 to 1/52
  • the twist factor Kc 1 of a single yarn is in a range of 81 to 87
  • the two-fold yarn is twisted in a direction opposite to the direction for twisting the single yarn
  • the twist factor Kc 2 of the two-fold yarn is in a range of 78 to 84.
  • the twist factor Kc 1 of the single yarn and the twist factor Kc 2 of the two-fold yarn are calculated by equations below.
  • Kc 1 T 1 / C 1
  • Kc 2 T 2 / C 1
  • T 1 indicates a twist number (time/m) of the single yarn
  • T 2 indicates a twist number (time/m) of the two-fold yarn
  • C 1 indicates a single yarn count (m/g).
  • the twist structure is stable, the yarn conjugative property is high, and thus a woven fabric with a delicate mesh texture and soft feeling can be obtained.
  • the obtained two-fold yarn is subjected to twist-fixing and used as warps and wefts to make a woven fabric.
  • the woven fabric construction include plain weave, twill weave, satin weave and the like. In a case of knitted fabric, any of flat knitting, circular knitting, and warp knitting can be applied. There is no particular limitation on the weave construction. When air is to be included in the knitted fabric, a double linkage pile textile is formed.
  • mat weave shown in FIG. 3 is particularly preferable, and this mat weave construction is referred to as plain weave and 3/3 mat weave.
  • the plain woven portion is formed of a warp composed of 8 yarns and a weft composed of 8 yarns, and has a plain weave construction.
  • the 3/3 mat woven portion is formed of a warp composed of 3 paralleled yarns and a weft composed of 3 paralleled yarns, and projects from the fabric surface. Accordingly, this weave construction has an anti-slip effect and is hardly broken because further fabric breakage can be prevented in the mat woven portion even when the plain woven construction is broken.
  • This woven construction is also referred to as a rip stop weave because the ripping of the fabric can be stopped.
  • the weight per unit (metsuke) of the protective suit fabric of the present invention is in a range of 100 to 340 g/m 2 , so that lighter and more comfortable work clothing can be provided. It is more preferable that the range is 140 to 300 g/m 2 , and particularly preferably 180 to 260 g/m 2 .
  • an antistatic fiber further is added to the fabric. This is to inhibit the charging of the fabric when the final product is in use.
  • the antistatic fiber include a metal fiber, a carbon fiber, a fiber in which metallic particles and carbon particles are mixed, and the like.
  • the antistatic fiber preferably is added in a range of 0.1 to 1 mass % relative to the spun yarn, and more preferably in a range of 0.3 to 0.7 mass %.
  • the antistatic fiber may be added at the time of weaving.
  • the measurement was performed in accordance with JIS K 7201-2.
  • the measurement was performed in accordance with ISO 11613-1999 at 180°C for 5 minutes.
  • the washing is performed 5 times in accordance with ISO 6330-1984, 2A-E specified in ISO 11613-1999.
  • the voltage immediately after electrification was measured by the frictional electrification attenuation measurement method specified in JIS L1094 5.4.
  • the total heat loss was measured in accordance with ASTM F 1868 Part C.
  • a stretch-broken spun yarn (twist number: 45 times per 10 cm in the Z direction) of a para-aramid fiber "Technora" (trade name) manufactured by Teijin, Ltd. was used.
  • the stretch-broken spun yarn was a black spun-dyed product and had a fineness of 8.0 tex (metric count: 1/125), a single-fiber fineness of 1.7 dtex, and an average fiber length of 100 mm.
  • the tow was cut into squares with a fiber length of 51 mm, and then a fiber bundle (sliver) was produced by carding blending.
  • the PBI fiber was an unbleached product (yellow).
  • Conex (trade name) (fiber length: 76/102 mm, bias cut, fineness: 2.2 dtex) manufactured by Teijin, Ltd. was used.
  • Belltron (trade name) (single-fiber fineness: 5.6 dtex, fiber length: 89 mm, square cut) manufactured by KB Seiren, Ltd. was used.
  • the sheath-core spun yarns were twisted by an up-twister to form a two-fold yarn.
  • the two-fold yarn was twisted in the S direction with a twist number of 60 times per 10 cm, and had a fineness of 625 dtex.
  • Example 2 The two-fold yarns of Example 1 were used for warp and weft. Using a rapier loom, a woven fabric having a weave construction of plain weave and 3/3 mat weave, as shown in FIG. 3 , was produced. The condition and result of the woven fabrics are summarized in Table 2.
  • a sheath-core spun yarn and a woven fabric were prepared in the same manner as Example 1 except that 73.9 mass% of the meta-aramid fiber "Conex" (trade name) (fiber length: 76/102 mm, bias cut, fineness: 2.2 dtex, beige) manufactured by Teijin, Ltd. was used for the sheath component.
  • the color of the blended yarn is shown in Table 1, and the condition and result of the woven fabric are summarized in Table 2.
  • a base fabric which is composed of a plain-woven fabric (mass: 77g/ m 2 ) made of a blended spun yarn including 85 mass% of the meta-aramid fiber (fineness: 2.2 dtex, fiber length: 76/102 mm, bias cut) and 15 mass% of wool, was laminated with a polytetrafluoroethylene film as a moisture-permeable waterproof layer to prepare an intermediate layer with a mass of 105 g/m 2 , and used.
  • a 16-shaft honeycomb fabric (mass: 213 g/ m 2 ) made of a blended spun yarn including 85 mass% of a meta-aramid fiber (fineness: 2.2 dtex, fiber length: 76/102 mm, bias cut) and 15 mass% of wool was used.
  • the result confirms that the woven fabric provided with the woven fabric of the present invention in the outer layer had high total heat loss.
  • the clothing having high total heat loss increases a heat flux generated from the body of a user during actual fire fighting, and a risk of heat illness caused by protection-oriented clothing is reduced, thereby increasing the comfort in wearing.
  • This high total heat loss is assumed to be due to the moisture content of the PBI fiber of 14.6%.
  • Example 2 These examples were performed in the same manner as Example 1 except that a blended product of the PBI fiber, the antistatic fiber and the meta-aramid fiber "Conex" (trade name) (fiber length: 76/102 mm, bias cut, fineness: 2.2 dtex, beige) manufactured by Teijin, Ltd. was used in place of the blended product of the PBI fiber and the antistatic fiber for the sheath component.
  • the oxygen index of the yarns is shown in Table 5, and the condition and result of the woven fabrics are summarized in Table 6. [TABLE 5] Spun-yarn structure Composition (mass%) Oxygen index (OI) Color tone Ex.
  • Sheath-core spun yarn Core: Para-aramid fiber 25.6 Sheath: PBI fiber (Yellow) 55.4 Meta-aramid fiber (Red) 18.5 Antistatic fiber 0.5 45.5 Orange with strong yellow
  • Sheath-core spun yarn Core: Para-aramid fiber 25.6 Sheath: PBI fiber (Yellow) 37.0, Meta-aramid fiber (Red) 36.9 Antistatic fiber 0.5 43.5 Orange
  • Example 7 These examples were performed in the same manner as Example 1 except that the blending ratio of each sheath component in the multilayer-structured spun yarn was set as shown in Table 7.
  • Table 7 the washing test was intended to measure the damage to the fabric.
  • the PBI was a stretch-broken fiber obtained by cutting the tow of the PBI fibers, and was an unbleached (yellow) product or a black spun-dyed product.
  • the blending of the sheath components was sliver blending. The respective fibers used are specifically described below.
  • Unmodified merino wool (average fiber length: 75 mm) made in Australia was used.
  • the wool was dyed in olive green by an ordinary method with an acid dye.
  • the wool had flame retardance due to the Zirpro process.
  • Viscose FR (trade name) (average fineness: 3.3 dtex, fiber length: 89 mm, mix cut) manufactured by Lenzing AG in Austria was used. The fiber was dyed in sky blue by an ordinary method with a reactive dye.
  • Cotton treated with the Proban process in which tetrakis(hydroxymethyl)phosphonium chloride was applied to the cotton by ammonia curing was used. In this case, the cotton was not dyed and remained unbleached (white).
  • PROTEX M (trade name) (average fineness: 3.3 dtex, fiber length 82/120 mm, bias cut) manufactured by Kaneka Corporation was used.
  • the fiber was dyed in oriental blue by an ordinary method with a cationic dye.
  • VECTRAN (trade name) (single-fiber fineness: 3.3 dtex (3 denier), fiber length 76/102 mm, bias cut) manufactured by KURARAY CO., LTD. was used.
  • the fiber had an oxygen index (OI) of 27 to 28.
  • OI oxygen index
  • the polyalylate fiber was a brown spun-dyed product.
  • the multilayer-structured spun yarn includes (i) the core component including the para-aramid fiber and (ii) the sheath component including the blended fiber of the PBI fiber and any of the other flame-retardant fibers (e.g., the flame-retardant wool, the flame-retardant rayon, the flame-retardant cotton, the flame-retardant acrylic fiber, the PEI fiber, the polyalylate fiber, or the PBO fiber), the multilayer-structured spun yarn can facilitate color matching by mixing colors, can improve the washing resistance in terms of preventing damage to the appearance of the fabric due to fibrillation, and can also achieve high heat resistance and high flame retardancy.
  • the core component including the para-aramid fiber and the sheath component including the blended fiber of the PBI fiber and any of the other flame-retardant fibers (e.g., the flame-retardant wool, the flame-retardant rayon, the flame-retardant cotton, the flame-retardant acrylic fiber, the PEI fiber
  • the heat-resistant protective suit that use the heat-resistant textile of the present invention is suitable for a fire fighter suit, and work clothing worn by ambulance crews, rescue workers, maritime lifeguards, military, workers at oil-related facilities, and workers at chemical facilities.
  • the core component includes the stretch-broken spun yarn of a para-aramid fiber and the sheath component includes the PBI fiber and a meta-aramid fiber, which are blended together, it is possible to achieve high heat resistance and high flame retardance, and to achieve textiles with a variety of color tones.

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  • Mechanical Engineering (AREA)
  • Textile Engineering (AREA)
  • Yarns And Mechanical Finishing Of Yarns Or Ropes (AREA)
EP16745032.9A 2015-03-18 2016-02-16 Mehrschichtiges gesponnenes garn, damit hergestelltes hitzebeständiges gewebe und hitzebeständige schutzkleidung Withdrawn EP3109351A4 (de)

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PCT/JP2016/054388 WO2016147779A1 (ja) 2015-03-18 2016-02-16 多層構造紡績糸とこれを使用した耐熱性布帛及び耐熱性防護服

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CN110004542A (zh) * 2019-03-08 2019-07-12 东华大学 一种含阻燃粘胶纤维和聚芳酯纤维的混纺纱的生产方法
CN111058134A (zh) * 2019-11-30 2020-04-24 黑牡丹纺织有限公司 复合牛仔纱线及其制作方法
EP3524720A4 (de) * 2016-10-05 2020-05-06 Toray Industries, Inc. Flammbeständiges gewebe
WO2021127454A1 (en) * 2019-12-19 2021-06-24 Southern Mills, Inc. Flame resistant fabrics with increased strength

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JP2019073834A (ja) * 2017-10-18 2019-05-16 帝人株式会社 難燃性布帛および繊維製品
JP7249569B2 (ja) * 2017-12-04 2023-03-31 クラレトレーディング株式会社 撚糸及びそれを用いた撚糸構造体
JP6599496B2 (ja) * 2018-03-07 2019-10-30 日本毛織株式会社 多層構造紡績糸とこれを使用した耐熱性布帛及び耐熱性防護服
CN109938520A (zh) * 2019-04-15 2019-06-28 刘国成 一种艾草抗菌驱蚊垫
CN112853561B (zh) * 2019-11-27 2023-03-24 太仓市泽记新材料有限公司 一种阻燃涤纶纱线及其制备方法
JP7280295B2 (ja) * 2021-02-03 2023-05-23 日本毛織株式会社 多層構造紡績糸、その製造方法、耐熱性布帛及び耐熱性防護服
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CN111058134B (zh) * 2019-11-30 2022-03-11 黑牡丹纺织有限公司 复合牛仔纱线及其制作方法
WO2021127454A1 (en) * 2019-12-19 2021-06-24 Southern Mills, Inc. Flame resistant fabrics with increased strength

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