JP2006249611A - Fabric having excellent flame retardancy and method for producing the same - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a fabric having excellent flame retardancy, feeling and comfortability; and to provide a method for producing the fabric. <P>SOLUTION: The fabric having excellent flame retardancy of ≥26.0 limited oxygen index is obtained by imparting a flame retardant substantially to the whole of the fabric, and further imparting the flame retardant to one-side surface so as to form a dot shape. The method for producing the fabric having the excellent flame retardancy comprises imparting the flame retardant to the whole fabric, and further imparting the flame retardant to one side surface of the resultant fabric so as to form the dot shape. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  [Technical Field] The present invention relates to a fabric material mainly used for apparel where flame retardancy is required and the front and back are used properly.

  Conventionally, flame-retardant processed fabrics include bedding side cloths, blankets, sheets and other beddings, curtains, curtains such as booklets, car seats, chairs such as sofas, flame retardant clothing such as uniforms and aprons, etc. There is.

  Flame retardant processing methods for obtaining these flame retardant processed products include, for example, a bath exhaust method that is applied in the bath simultaneously with dyeing, or a pad / dry method in which a fabric is immersed in a processing agent and a certain amount is squeezed and dried. There is a law.

  However, in these methods, the flame retardant is uniformly attached (penetrated) to the fabric, and the attached state of the flame retardant is generally difficult to understand.

  Moreover, since a high degree of flame retardancy is required for curtains, booklets, and chairs, the flame retardant adheres to the back surface in a uniform film state. As these coating methods, knife coating, reverse roll coating, gravure coating or the like is used. Various proposals have heretofore been made for the method of attaching such a flame retardant. For example, there are proposals for fabrics used in these methods and production methods thereof (for example, Patent Documents 1 to 3).

  On the other hand, flame retardant fibers include polyvinyl chloride, modacrylic, polyclar, aramid, phenolic, polyphenylene sulfate, etc., in which the fiber material itself is difficult to burn. In addition, there are flame retardant acrylics and flame retardant polyesters which are made into a fiber by adding a flame retardant before copolymerization or spinning with the flame retardant.

  In addition, it is used for adhesives for bonding interlining, adhesives for chair upholstery and reinforcing fabric, anti-slip between mat and floor, and work gloves as dots-like processing agents added Non-slip resin can be mentioned, and various proposals have been made conventionally.

  For example, there is a proposal of a method for manufacturing artificial leather in which a functional material is applied in the form of dots or an adhesive is bonded together using an adhesive in the form of dots (for example, Patent Documents 4 to 6).

However, in clothing applications that currently have a certain level of flame retardancy and require a soft texture and comfortable wearing, these fiber uses and methods are in terms of texture, dyeability, comfort and cost. It was not satisfactory.
JP-A 63-246112 JP-A-4-119172 JP-A-4-352876 Japanese Examined Patent Publication No. 63-063673 Japanese Patent Laid-Open No. 5-051876 Japanese Patent Publication No. 01-030957

  An object of the present invention is to solve the problems of the prior art and provide a fabric excellent in flame retardancy, texture and comfort and a method for producing the same.

  The present invention employs the following means in order to solve such problems.

  That is, the fabric product of the present invention has a flame retardant applied to substantially the entire fabric product, and a flame retardant is further applied in the form of dots to one side surface. A fabric having excellent flame retardancy, characterized by having a limiting oxygen index of at least 26.0.

  The method for producing a fabric product having excellent flame retardancy according to the present invention is characterized in that after the flame retardant is applied to the entire fabric, the flame retardant is applied in a dot shape to one surface of the fabric. This is a method for producing a fabric having excellent properties.

  According to the present invention, a fabric excellent in flame retardancy, texture and comfort is provided.

  Hereinafter, the present invention will be described in more detail.

  The flame-retarded fabric of the present invention is a fiber structure in which a flame retardant is applied to substantially the entire fabric, and a flame retardant is further applied in a dot shape to one surface. The fiber structure is a fabric having excellent flame retardancy, wherein the fiber structure has a critical oxygen index of 26.0 or more.

  Here, “a flame retardant is applied to substantially the entire fabric object, and a flame retardant is further applied to the surface on one side in the form of dots” means that the fabric object is substantially the entire. The flame retardant is uniformly applied to the surface, and the one side surface is further provided with a flame retardant in the form of dots.

  Here, “provided in the form of dots” means that “on one side of the surface, a discontinuous state is formed in the form of dots and a flame retardant is applied”. The size of each dot is preferably about 500 μm to 2000 μm, and more preferably about 1000 μm to 1200 μm. The shape is preferably a circle or a 4-6 hexagon.

  Since the fabric of the present invention is suitably used as clothing, it is preferable to use a dyed fabric.

  The dyed fabric according to the present invention is a fiber structure to which a flame retardant is applied as described above, and the fiber structure has at least a critical oxygen index of 26.0 or more.

  When the critical oxygen index is less than 26.0, the intended purpose of the present invention cannot be achieved because of the possibility of self-combustion depending on atmospheric conditions such as temperature, humidity, and wind.

  Next, the flame retardant that can be used in the present invention is a processing agent that suppresses the burning of the fiber processed fabric and is called a flame retardant or flame retardant, and N, P as elements having a flame retardant effect , As, Sb, Bi, and the like are composed of a Group V halogen element and a Group VII halogen element.

  The flame retardant that can be used in the present invention can be classified into an organic type and an inorganic type.

  Examples of the organic system include phosphorus-based phosphate esters, phosphazene compounds, melamine phosphate-reactive phosphate esters, and phosphate amides. Examples include nitrogen-containing guanidine compounds, melamine cyanurates, and triazine compounds. Examples include silicon-based silicon polymer powder.

  On the other hand, the inorganic type includes metal hydroxide type aluminum hydroxide and magnesium hydroxide. Examples of the phosphorus compound include ammonium phosphate, red phosphorus, zirconium phosphate, and ammonium polyphosphate. There are metal oxides such as antimony trioxide, zinc borate, molybdenum oxide, silica, and alumina.

  The post-processing of flame retardant has three elements: fiber material, flame retardant, and processing technology. The flame retardant, processing method, etc. differ depending on the material. Specifically, most of cotton and cellulose fibers are phosphorus compound derivatives, and representative examples include N-methyloldimethylphosphonopropionamide, tetrakishydroxymethylphosphonium sulfate / urea condensate, and the like. As the rayon fiber, “Toughban” Toyobo, which has been made flame-retardant from raw yarn, “DFG” (Daiwabo) and the like are used.

  Polyester fibers mainly include “Him” (Toyobo) and “Trevira” (Hoechst), a flame-retardant fiber made from a yarn that is copolymerized with a flame retardant of a phosphorus compound and polyester. Moreover, a method of exhausting a halogenated cycloalkane compound such as hexabromocyclododecane (HBCD), which is a typical post-processing flame retardant, in a dyeing bath is common. In addition, there is a method of applying phosphate esters by exhaustion or a thermosol method.

  In general, when an aliphatic halogen compound is added to nylon, coloration tends to occur. In addition, aromatic halogen compounds have a problem of poor compatibility with nylon and poor spinnability. Phosphoric esters also block the amino end groups of nylon and reduce dyeing seats.

  As post-processing, decabromobiphenyl oxide, urea / thiourea polycondensate, guanidine phosphate derivatives and the like are used. The acrylic fiber mainly employs a method of copolymerizing a halogen-containing monomer. Examples of the copolymerization monomer include tribromoneopentyl acrylate, α-chloroacrylonitrile, copolymerization of vinyl bromide and vinylidene chloride.

  In general, the limiting oxygen index (LOI value) is taken up as one of the measures showing the flame retardancy of a substance. The critical oxygen index (LOI value) is defined by the JIS K 7201 B-1 method.

  The LOI value is the oxygen volume% of the atmosphere required for the sample to continue to burn and burn. Therefore, it can be said that a sample having a larger value is more difficult to burn. As combustible fiber, cotton: 17-19, acrylic: 20, nylon, polyester: 20-22, wool: 24-26, modacrylic ("Kanekaron"): 27-29 as flame retardant fiber, flame retardant polyester (Heim) ): 28-32, polyvinyl chloride: 35-37, polyvinylidene chloride: 45-48, aramid fiber: 30 as heat resistant fiber, polyphenylene sulfide: 34, carbonized fiber ("pyromex"): 55-60, pitch Carbon fiber: 60 or more, fluorine fiber ("Teflon (registered trademark)" fiber) 95, and the like.

  It is preferable that the area of the flame retardant imparted in the form of dots is in the range of 50 to 85% with respect to the area of one side surface.

  When the area of the flame retardant imparted in the form of dots is less than 50% relative to the area of one side, it is difficult to obtain flame retardant performance, and the area of the flame retardant imparted in the form of dots exceeds 85% The texture becomes hard and the functionality (comfort) of the material cannot be fully exhibited.

Moreover, it is preferable that the number of dots of the flame retardant imparted in the form of dots is in the range of 25 to 150 / cm ² . A more preferable number is in the range of 30 to 100 / cm ² .

  Note that Japanese Patent Publication No. 63-063673 proposes a fiber sheet to which a functional agent is applied in the form of dots, but the average diameter of one dot is 30 to 500 μm, which is larger than this. It is said that it is too rough and the difference from the conventional product is not clear. In addition, an ink jet method has been proposed as a method for applying dots.

On the other hand, the basic idea of the technical idea of the present invention is that the area occupied by the flame retardant is in the range of 50 to 85% and the number of dots is in the range of 25 to 150 / cm ^2. When the occupied area is 50% and the number of dots is 150 / cm ² , it is about 650 μm, which is outside the range of 500 μm of the invention disclosed in Japanese Patent Publication No. 63-063673. Incidentally, the maximum dot diameter is about 2080 μm when the occupied area is 85% and the number of dots is 25 / cm ² . The air flow is a numerical value indicating how much air can pass through the fabric. The higher the value, the better the air permeability, but even if it is too high, it is not suitable for some applications.

On the other hand, when exercising at zero airflow, it is easy to get stuffy and lacks comfort. The amount of ventilation that can maintain comfort as a flame-retardant clothing may be ² cc / sec / cm ² or more.

  The fabric according to the present invention is a woven fabric, a knitted fabric, or a nonwoven fabric made of natural fibers, chemical fibers, or synthetic fibers. The material is not particularly limited, but contains 30% by weight or more of synthetic fibers such as nylon, polyester, and acrylic. The fabric material is more preferable in terms of durability, dimensional stability, heat resistance, and cost.

  In addition, a fabric containing 30% by weight or more of synthetic fiber is preferable because it can be easily processed even when dyeing and flame-retarding in a bath.

  The use of the fabric product according to the present invention is not particularly limited, but the fabric product is a combination of the application of the flame retardant and the application of dots. This is optimal because the dots are not visible and the appearance is not impaired. Apparel that requires flame resistance includes work clothes and aprons in places where fire is used, work clothes in places where there is a risk of explosion, ignition, and fire, military, self-defense forces, fire clothes, etc. The fabric according to the present invention is preferably used for these applications. In addition to clothing, it can be used for curtains, pocketbooks, curtains, upholstery and the like.

  As a production method of the present invention, a dye and a flame retardant are treated in the same bath at the time of dyeing and exhausted and adsorbed on the entire fiber, or a flame retardant is applied to a dyed fabric by a pad / dry / curing method, a pad / dry / steam method. Then, the entire fiber is exhausted and adsorbed by the pad / steam method or the like. For example, in the case of polyester, specifically, in the case of simultaneous processing with dyeing, a liquid dyeing machine is used to immerse in a treatment liquid in which the disperse dye and the flame retardant are 10% owf at a bath ratio of 1:15. For 30 minutes at 130 ° C. The pad / dry / cure method involves dipping in a processing solution diluted to a flame retardant concentration of 20% by weight, squeezing at a squeezing rate of 70%, drying at 110 ° C. for 5 minutes, and then at 190 ° C. Heat set for 1 minute. Thereby, a flame retardant is exhausted and adsorbed to the whole fiber, and a flame retardant is provided to dot shape after that.

  As a preferable dot applying method, a printing method using a flat screen or a rotary screen or a gravure roll method is preferable. Although it is possible with the spray method, it is difficult to obtain the target quality and performance due to insufficient dot size variation and insufficient uniform dispersibility. Although an ink jet method is also possible, generally the size of dots tends to be small.

The flame retardant processing agent for dots requires a certain degree of viscosity, and if the viscosity is low, the processing agent penetrates and penetrates to the opposite side of the print, which makes the appearance of the material poor. Therefore, in order to increase the viscosity, a thickener or a crosslinking agent is used. In addition, for the purpose of preventing penetration, it is one of the measures to perform water-repellent processing before dot processing. For the purpose of improving dot adhesion and washing durability, it is important to add a resin to the flame retardant. As the resin at this time, it is preferable to select a resin that does not deteriorate the flame retardancy as much as possible. Specifically, acrylic, urethane, vinyl, and silicone resins are preferably used. Moreover, it is preferable that the adhesion amount of a flame retardant processing agent is the range of 30-150 g / m < ² > from the point of a flame retardance performance and texture.

  EXAMPLES Hereinafter, although an Example demonstrates this invention further in detail, this invention is not limited to these Examples. The evaluation and measurement in the examples were performed by the following methods.

<Limit oxygen index (LOI value)>
Measured according to JIS K 7201 B-1.
<Combustion test>
JIS L 1091 A-1 method (45 ° micro burner method)
<Air flow rate>
Measured by JIS L 1096 Breathability Method A (Fragile Type Method).
<Area ratio of flame retardant applied in the form of dots>

  The percentage of the total area of the flame retardant imparted in the form of dots as seen from the upper side of the fabric with respect to the fabric area. Even if the dots are chevron, it is not the surface area of the dots but the bottom area of the dots, and the ratio of the total area to the fabric area. Specifically, it is a ratio obtained by taking an enlarged copy from the upper surface, obtaining the total area of the dots, and dividing by the area of the entire fabric.

  Specifically, a square sample fabric having a fabric area of 10 cm × 10 cm is prepared, a color copy having an area expansion ratio of 10 times is taken on the surface of the fabric where the dot-shaped flame retardant is applied, and the dot portion is visually observed on the copy paper surface. The total area of the fabric and the total dot area were measured and calculated. The n number was 3, and the average value was used.

Example 1
A spun yarn 40S / 2 (twist yarn 990 t / m) composed of 50% nylon 66 fiber of 3 dtex × 38 mm and 50% cotton was woven into a plain structure of 88 pieces / inch and 58 pieces / inch.

  Using this dough, it was dyed through normal scouring, bleaching and drying steps. The dyeing conditions were: Sule dye (Mikethren Gold Orange G super fine: 1.9% by weight, Mikethren Red FFB super fine: 0.2% by weight, Indanthren Blue CLF coll 1.1% by weight) The dough was dipped, squeezed at a squeezing rate of 60%, and then dried. Next, after dipping in a normal reducing agent and squeezing, a steam treatment at 103 ° C. for 90 seconds was performed, followed by neutralization, washing with water and drying.

  Next, in order to perform flame retardant processing on the entire fabric, 40% by weight of N-methyloldimethylphosphonopropionamide (Pyrobatex CP-NEW CONC made by Ciba Geigy) as a flame retardant, 10% by weight of melamine resin, catalyst (75% phosphoric acid) The dough was immersed in a liquid consisting of 3% by weight, squeezed at a squeezing ratio of 60%, then dried at 150 ° C. × 1 minute, baked at 170 ° C. × 1 minute, then washed with water and dried. Next, in order to prevent the flame retardant of the dot from penetrating to the surface, the fabric is immersed in a liquid consisting of 5% by weight of a fluorine-based water repellent (concentration 20% product), and then the liquid is drawn at a drawing rate of 60%. , Dried at 130 ° C. for 1 minute, and baked at 150 ° C. for 1 minute.

  Next, 78 parts of powder bromo flame retardant (Bigor DBS-77 manufactured by Daikyo Chemical Co., Ltd.), 16 parts of acrylic resin (40% concentration), cell methylcellulose (resinol HE-100 concentration 6) % Product) A paint consisting of 6 parts was prepared as a flame retardant finish. Using this flame retardant finishing agent, printing was performed with a rotary screen printing machine. The screen at that time was 105 mesh made of nickel, and the diameter of the cage was 10 mm. The processing speed was 15 m / min.

The adhesion amount at this time was 90 g / m ² before drying. The print finish was dried at 130 ° C. for 1 minute and baked at 170 ° C. for 1 minute. The critical oxygen index, burn test, dot occupancy area, number of dots, and air flow rate of the finished fabric were as shown in Table 1, and did not feel stiff. Using this fabric, a coverall to be worn at the welding site was created and worn. Even if sparks adhere to the fabric, it can be worn safely without burning. Moreover, since it was breathable, it did not feel stuffy.

Example 2
Using 3dtex x 38mm nylon 66 40% 1.7dx x 40mm flame retardant rayon 30% and cotton 30% spun yarn 40S / 2 (twisted yarn 990t / m), 88 vertical / inch, horizontal Weaved with a flat structure of 58 pieces / inch. This dough was dyed through the scouring and drying process under the same conditions as in Example 1. Next, the entire fabric was subjected to flame retardant processing and water repellent processing under the same conditions as in Example 1.

Next, the same flame retardant processing agent for dots as in Example 1 was used. Using this flame retardant finishing agent, printing was performed with a rotary screen printing machine. At that time, the screen was made of 85 mesh made of nickel, the diameter of the cage was 10 mm, and the processing speed was 15 m / min. The adhesion amount at this time was 105 g / m ² before drying.

  The print finish was dried at 130 ° C. for 1 minute and baked at 170 ° C. for 1 minute. The critical oxygen index, burn test, dot occupancy area, number of dots, and air flow rate of the finished fabric were as shown in Table 1, and did not feel stiff. This fabric was used to create and wear cooking. Because it is flame retardant, it could be worn safely by the elderly.

Comparative Example 1
Processing was performed using the same materials and conditions up to the dyeing process of Example 1. The physical properties after processing are shown in Table 1. The critical oxygen index was as low as 20.0. As a result of the combustion test, complete combustion occurred in Category 1.
Comparative Example 2
The entire fabric of Example 1 was processed with the same materials and conditions up to flame retardant processing. The physical properties after processing are shown in Table 1. The critical oxygen index was as low as 24.5, and the result of the combustion test was Category 2.

Claims (8)

  A flame retardant is applied to substantially the entire fabric product, and a flame retardant is further applied to the surface on one side in the form of dots, and the critical oxygen index of the fabric product is at least 26.0 or more. A fabric product excellent in flame retardancy characterized by being.   2. The fabric product having excellent flame retardancy according to claim 1, wherein the application area of the flame retardant applied in the form of dots occupies 50 to 85% with respect to the area of one surface. Claim 1 or 2 excellent fabric material flame retardant according number of dots of the flame retardant granted in dots is characterized in that 25 to 150 pieces / cm ^2. The fabric having excellent flame retardancy according to any one of claims 1 to 3, wherein the air flow rate is ² cc / sec / cm ² or more.   The fabric product excellent in flame retardancy according to any one of claims 1 to 4, wherein the fabric product comprises 30% or more of synthetic fibers.   6. A clothing article comprising the fabric product having excellent flame retardancy according to any one of claims 1 to 5 on the back side of a surface provided with a flame retardant in the form of dots.   The flame retardant having excellent flame retardancy according to any one of claims 1 to 6, wherein after the flame retardant is applied to the entire fabric, the flame retardant is applied in a dot shape to one surface of the fabric. Production method.   The method for producing a fabric product having excellent flame retardancy according to claim 7, wherein a flame retardant is applied to the entire fabric after or simultaneously with the dyeing.