JP2007105403A - Fire-retardant nonwoven-fabric and fire retardant mattress using the same - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To obtain a mattress having excellence in processability, handleability, the feeling of touch and design, hardly obtained in a conventional, fire-retardant nonwoven-fabric, and satisfying the specifacations of the cigarette test of 16CFR part 1632 (USA), further satisfying the specifications of the cigarette test of 16CFR part 1632 (USA) and the flammability test of TB603 (USA, Cal.). <P>SOLUTION: The fire retardant fabric composed of fibers consisting of halogen-containing fibers (A) of 40-90 wt.% and polyester fibers (B) of 10-60 wt.% or the fire retardant fabric composed of fibers consisting of the halogen-containing fibers (A) of 40-90 wt.%, the polyester fibers (B) of 10-60 wt.% and fire retardant cellulose fibers (C) of 0-50 wt.% is used to protect an inner structural body of the mattress. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to bedding products such as beds and mattresses that require high flame retardancy.

  In recent years, the demand for ensuring the safety of clothing, food and housing has increased, and the need for flame retardant materials has increased. Under such circumstances, there is a strong demand for imparting flame retardancy to materials used for bedding such as mattresses.

  One of the flame retardant standards for mattresses in the United States is the tobacco test 16CFR part 1632.

  In general-purpose mattresses, flammable materials such as urethane foam are used as the internal structure constituting the mattress for comfort during use, and between the internal structure and the side ground, In order to give bulkiness, a nonwoven fabric using a general-purpose material polyester as a main material is used.

  A mattress using a non-woven fabric made of polyester passes when the tobacco test 16CFR part 1632 is conducted, the polyester is easily melted by the tobacco heat, thereby preventing the heat transfer of the flammable urethane foam which is the internal structure. However, since the polyester itself is flammable, there is a problem that it has poor flameproofing properties. In order to prevent the mattress from flameproofing, it is important to prevent the flame-retardant material, which is an internal structure, from spreading from the side fabric and the nonwoven fabric for a long time. Moreover, the flameproof material of the side fabric or the nonwoven fabric must not impair the requirements such as comfort and bulkiness of furniture and bedding.

  Various flame retardant fibers and disaster prevention agents have been studied in the past, but they have both the above-mentioned tobacco test and flame resistance, and have sufficient requirements for furniture and bedding materials. The nonwoven fabric has not yet appeared.

  For example, a mattress using a halogen-containing fiber alone as a non-woven fabric as a flame retardant fiber has the effect of lowering the temperature of tobacco, which is a heat source, and therefore passes the US tobacco test 16CFR part 1632, but the processing method of the non-woven fabric is limited. There were other problems such as inferior bulkiness.

  More recently, the California Flammability Test TB603 was established as a flame retardant standard for mattresses. This standard is such that when the burner flame is radiated to the mattress for a certain period of time, the amount of heat generated by the combustion of the mattress falls within a specified value. In addition to the flameproofing performance that prevents the spread of the ignited mattress, the required properties of the nonwoven fabric are to prevent the flame of the burner from directly hitting flammable materials such as cotton and urethane foam, which are the internal structure of the mattress. The carbonized film forming performance of the nonwoven fabric is required. For this reason, when polyester, which is a general-purpose material, is used as the main material, polyester cannot become a carbonizing component, so when forcedly burned, holes are formed by melting and burning, and the structure can be maintained. The fireproofing performance that prevents flames from being applied to the cotton and urethane foam used in the mattress was not sufficient.

A large amount of flame retardant is added as a material that improves the defects of these bedding materials and has excellent texture, hygroscopicity, tactile sensation, and stable flame resistance, which are required as general characteristics. Proposed interior fiber products (Patent Document 1) and textile products for bedding (Patent Document 2) using a flame-retardant fiber composite that combines highly flame-retardant halogen-containing fibers and other fibers that are not flame-retardant However, when the US tobacco test 16CFR part 1632 is performed using these bedding products, there are cases where the test does not pass. That was difficult to say. Moreover, the flame-retardant nonwoven fabric (patent document 3) which has bulkiness from the fiber and halogen-containing fiber which are essentially flame-retardant, and the flame-retardant nonwoven fabric which consists of a halogen-containing polyacrylonitrile fiber and the fiber which supports it at the time of combustion ( Patent Document 4), flame retardant nonwoven fabrics (Patent Document 5) composed of flame retardant rayon fibers, flame retardant acrylic fibers, and flame retardant melamine fibers have been proposed, but these methods are highly flame retardant. Halogen fibers cannot maintain their fiber form due to combustion, resulting in insufficient strength of the carbonized film during combustion. there were. In addition, organic heat-resistant fibers used for maintaining the fiber form during combustion and inherently flame retardant fibers are generally expensive and disadvantageous in terms of cost.
JP 05-106132 A JP 05-093330 A WO03 / 023108 US2004 / 0062912A1 US2004 / 0097156A1

  The present invention is a problem that has been difficult to solve with conventional flame-retardant nonwoven fabrics, that is, a mattress that has good processability, texture, touch, and good design, and that passes US tobacco test 16CFR part 1632, and further It was made to obtain a mattress that passed the California Flammability Test TB603 with Test 16 CFR part 1632.

  As a result of intensive studies to solve the above problems, the present inventors have determined that the fiber configuration of the nonwoven fabric used for the mattress is as follows: 1) 40% to 90% by weight of the halogen-containing fiber (A) and 10% of the polyester fiber (B). ~ 60 wt%, or 2) Halogen-containing fiber (A) 40-90 wt%, polyester fiber (B) 10-60 wt%, and flame retardant cellulosic fiber (C) 0-50 wt% , When conducting a tobacco test by a method based on the US tobacco test 16CFR part 1632, it was found that the combustion temperature of the tobacco was lowered, the transfer of heat to the urethane foam as an internal structure was suppressed, and the US tobacco test 16CFR part 1632 was passed. The present invention has been completed.

That is, the present invention is a mattress using a flame retardant nonwoven fabric composed of 40 to 90% by weight of a halogen-containing fiber (A) and 10 to 60% by weight of a polyester fiber (B), and tobacco is placed on the mattress. Mattress (Claim 1), halogen-containing fiber (A) 40 to 90% by weight, polyester fiber The mattress according to claim 1 (Claim 2) and halogen-containing fiber (A) using a flame retardant nonwoven fabric containing (B) 10 to 60% by weight and flame retardant cellulosic fiber (C) 0 to 50% by weight. 3) A mattress according to claim 2 using a flame retardant nonwoven fabric containing 4% by weight or less of an antimony compound (claim 3), halogen-containing fiber (A) 40-60% by weight, polyester 10 to 25% by weight of the fiber (B) and 30 to 50% by weight of the flame retardant cellulosic fiber (C), and the total of the three components is 100% by weight, and the weight% of (A) ≧ (C) A mattress according to claim 2 or claim 3 (claim 4), 40 to 60% by weight of a halogen-containing fiber (A), 10 to 10% of a polyester fiber (B). 25% by weight, and 30-50% by weight of the flame-retardant cellulosic fiber (C), and the total of the three components is 100% by weight, and the weight% of 25 ≧ (A)-(C) ≧ 0 A mattress using a non-flammable nonwoven fabric, with a T-shaped burner set vertically at a position 42 mm from the side of the mattress and a T-shaped burner set horizontally at a position 39 mm from the top surface of the mattress. Use propane gas as gas The force is 101 KPa, the gas flow rate is 12.9 L / min on the top surface, 6.6 L / min on the side surface, the flame time is 50 seconds on the side surface and 70 seconds on the top surface, and the maximum heat release amount for a total observation time of 30 minutes is less than 200 Kw. The mattress according to any one of claims 2 to 4, wherein the cumulative heat release amount for the first 10 minutes is less than 25 MJ (claim 5), and the basis weight of the flame-retardant nonwoven fabric is 250 to 400 g claim 1, wherein the mattress, which is a / m ² (claim 6), any one of claims 2 to 5 weight per unit area of the flame-retardant nonwoven fabric is characterized in that it is a 300 to 400 g / m ² The halogen-containing fiber (A) is 30 to 70% by weight of acrylonitrile, 70 to 30% by weight of halogen-containing vinyl and / or halogen-containing vinylidene monomer, and The mattress according to any one of claims 1 to 7, wherein the antimony compound is contained in an amount of 0 to 4 parts by weight per 100 parts by weight of an acrylic polymer comprising 0 to 10% by weight of a vinyl monomer copolymerizable therewith. The mattress according to any one of claims 1 to 8, wherein the polyester fiber (B) is at least one fiber selected from the group consisting of a polyester fiber having a melting point exceeding 200 ° C and a low melting point binder fiber. (Claim 9), a low-melting-point binder fiber of the polyester fiber (B) is a fiber made of a single component of a low-melting polyester, a fiber made of a composite of a polyester having a melting point exceeding 200 ° C and a low-melting polyester, a melting point of 200 ° C The fiber according to claim 1, wherein the fiber is at least one fiber selected from the group consisting of a fiber composed of a composite of an excess polyester and a low melting point polyolefin. The thigh (Claim 10), the flame retardant cellulose fiber (C) is a phosphate ester compound, a halogen-containing phosphate ester compound, a condensed phosphate ester compound, a polyphosphate compound, red phosphorus, an amine compound, boron A flame retardant selected from the group consisting of acids, halogenated compounds, bromides, urea-formaldehyde compounds, phosphate-urea compounds, ammonium sulfate, cellulose selected from the group consisting of cotton, hemp, rayon, polynosic, cupra, acetate and triacetate The mattress according to any one of claims 1 to 10 (claim 11) and the flame-retardant cellulosic fiber (C) selected from silicic acid or aluminum silicate. The mattress according to claim 1, wherein the mattress is a rayon fiber containing 20 to 50% by weight of a flame retardant. Claim 12) about.

  The mattress using the flame-retardant nonwoven fabric of the present invention has the ability to suppress the transfer of heat to the inside of the mattress and reduce the combustion of the urethane foam, which is an internal structure, by lowering the combustion temperature of tobacco in the US tobacco test 16CFR part 1632. It is possible to have high flame retardance that hinders.

  The mattress of the present invention relates to a mattress using a flame retardant nonwoven fabric.

  The flame-retardant nonwoven fabric referred to here is 1) a flame-retardant nonwoven fabric comprising 40 to 90% by weight of a halogen-containing fiber (A) and 10 to 60% by weight of a polyester fiber (B), or 2) a halogen-containing fiber ( A) A flame retardant nonwoven fabric containing 40 to 90% by weight, polyester fiber (B) 10 to 60% by weight, and flame retardant cellulosic fiber (C) 0 to 50% by weight, and a mattress using this nonwoven fabric In accordance with US tobacco test 16 CFR part 1632, when the tobacco test was performed, the temperature of the tobacco was lowered to suppress the transfer of heat to the urethane foam as the internal structure, and the US tobacco test 16 CFR part 1632 was passed. Furthermore, the halogen-containing fiber (A) is 40 to 60% by weight, the polyester fiber (B) is 30 to 50% by weight, the flame retardant cellulosic fiber (C) is 10 to 25% by weight, and the total of the three components is 100. In addition to the tobacco test, when the nonwoven fabric is exposed to a flame, the nonwoven fabric is 25% by weight and the weight percent of 25 ≧ (A)-(C) ≧ 0. The flame is shielded by carbonizing while maintaining the form of the fiber, and passes the flammability test TB 603 in California, USA.

  The halogen-containing fiber (A) used in the present invention is a component used for improving the flame retardancy of a nonwoven fabric, and is a component that has an effect of assisting in self-extinguishing a flame by generating an oxygen-deficient gas during combustion. Examples of the halogen-containing fiber (A) used in the present invention include homopolymers and copolymers of halogen-containing monomers such as vinyl chloride and vinylidene chloride, and monomers copolymerizable with these halogen-containing monomers such as acrylonitrile and styrene. , Vinyl acetate, a copolymer with acrylic acid ester or the like, or a fiber made of a graft polymer in which a halogen-containing monomer is grafted to a PVA polymer, but is not limited thereto. Examples of the halogen-containing fibers (A) include modacrylic fibers that are fibers made of a copolymer of a halogen-containing monomer and acrylonitrile.

  It is preferable that a flame retardant is added to the modacrylic fiber in order to enhance the flame retardancy of the batting. Specific examples of the flame retardant include antimony trioxide, antimony pentoxide, antimonic acid, and antimony oxychloride. Antimony compounds, stannic oxide, metastannic acid, stannous oxyhalide, stannic oxyhalide, stannous hydroxide, tin tetrachloride and other Sn compounds, zinc oxide and other Zn compounds, magnesium oxide Mg compounds such as magnesium hydroxide, Mo compounds such as molybdenum oxide, Ti compounds such as titanium oxide and barium titanate, N compounds such as melamine sulfate and guanidine sulfamate, ammonium polyphosphate, dibutylaminophosphate P compounds such as aluminum hydroxide, aluminum sulfate, silicic acid Natural or synthetic mineral products such as Al compounds such as minium, Zr compounds such as zirconium oxide, Si compounds such as silicate and glass, kaolin, zeolite, montmorillonite, talc, perlite, bentonite, vermiculite, diatomaceous earth, graphite , Halogenated compounds such as chloroparaffin, hexabromobenzene, hexabromocyclododecane, and the like. Moreover, you may use complex compounds, such as magnesium stannate, zinc stannate, and a zirconium stannate. These may be used alone or in combination of two or more. Specific examples of the modacrylic include, but are not limited to, Kanekalon manufactured by Kaneka Corporation and SEF (SEF) manufactured by Solutia.

  The polyester fiber (B) used in the present invention is a component for imparting excellent bulkiness and durability to the batting of the present invention, and at the same time, melts during combustion so that the melt covers the carbonized film. Has the effect of improving the strength of the carbonized film. Specific examples of the polyester fiber (B) include a polyester fiber having a general-purpose melting point exceeding 200 ° C., a low-melting-point binder fiber, and a flame-retardant polyester fiber. These may be used alone or in combination of two or more. You may use it in combination. The low melting point binder fiber is at least one selected from the group consisting of a fiber consisting of a single component of a low melting point polyester, a fiber consisting of a composite of a normal polyester and a low melting point polyester, and a fiber consisting of a composite of a normal polyester and a low melting point polyolefin. One fiber is preferred. Generally, the melting point of low-melting polyester is approximately 110 to 200 ° C, the melting point of low-melting polypropylene is approximately 140 to 160 ° C, and the melting point of low-melting polyethylene is approximately 95 to 130 ° C. There is no particular limitation as long as it has the ability. Examples of the low-melting-point binder fiber include, but are not limited to, Safmet (4.4 dtex × 51 mm, melting temperature 110 ° C.) manufactured by Toray Industries, Inc.

  The flame-retardant cellulosic fiber (C) used in the present invention is a cellulosic fiber attached with a flame retardant made by post-processing using a flame retardant, silicic acid or / and as a flame retardant to the cellulosic fiber. Silicate-containing cellulosic fibers containing aluminum silicate are used. The flame-retardant cellulosic fiber used in the present invention is a component used for improving the flame retardancy and maintaining the strength of the flame-shielding non-woven fabric, giving comfort such as excellent texture and moisture absorption, and burning It is the main component in forming a strong carbonized film that is sometimes effective in forming a carbonized film. Flame-retardant cellulosic fibers are harder than cellulosic fibers, so there is less loss due to combustion and the remaining carbonized components are larger than cellulosic fibers, forming a strong carbonized film. It is an essential component when

  Specific examples of cellulosic fibers that are substrates for flame retardant cellulosic fibers include cotton, hemp, rayon, polynosic, cupra, acetate and triacetate, which may be used alone or in combination of two or more. May be used.

  Triphenyl phosphate, tricresyl phosphate, trixylenyl phosphate, trimethyl phosphate, triethyl are used as the flame retardant used to make the cellulose fiber used in the cellulose fiber with the flame retardant attached by post-processing. Phosphate, cresylphenyl phosphate, xylenyl diphenyl phosphate, resorcinol bis (diphenyl phosphate), 2-ethylhexyl diphenyl phosphate, dimethylmethyl phosphate, triallyl phosphate (leophos), aromatic phosphate ester, phosphonocarboxylic acid amide derivative, Phosphate ester compounds such as tetrakis / hydroxymethylphosphonium derivatives, N-methyloldimethylphosphonopropionamide, tris (chloroethyl) phosphoric acid Fate, trisdichloropropyl phosphate, tris-β-chloropropyl phosphate, chloroalkyl phosphate, tris (tribromoneopentyl) phosphate, diethyl-N, N-bis (2-hydroxyethyl) aminomethyl phosphate, tris (2,6 -Halogenated phosphoric acid ester compounds such as dimethylphenyl) phosphate, condensed condensed phosphoric acid ester compounds such as aromatic condensed phosphoric acid esters and halogenated condensed phosphoric acid esters, ammonium polyphosphate amide, polychlorophosphonate, etc. Polyphosphate compounds, polyphosphate ester compounds such as polyphosphate carbamate, red phosphorus, amine compounds, boric acid, halogen compounds, bromides, urea-phosphates such as formaldehyde compounds and phosphorus-containing aminoplasts- Examples include urea compounds, ammonium sulfate, and guanidine-based condensates. These may be used alone or in combination of two or more. These flame retardants are attached to the cellulosic fibers, but the amount attached is 6 to 25% by weight with respect to the cellulosic fibers in order to maintain the flame retardancy of the flame-shielding nonwoven fabric. From the standpoint of not impairing the texture of the flame-shielding nonwoven fabric, it is attached to be 35% by weight or less with respect to the entire flame-shielding nonwoven fabric.

  The silicic acid-containing cellulose fiber is a cellulose fiber containing 20 to 50% of silicic acid or / and aluminum silicate as a flame retardant, and usually has a fineness of about 1.7 to 8 dtex and a cut length of about 38 to 128 mm. Specific examples thereof include, for example, Visil of Sateri Co., which contains about 30% of silicic acid in the fiber, and Sateri, which contains about 33% of aluminum silicate in the fiber. Visil AP) of the company), but is not limited thereto.

In the present invention, in order to pass the US tobacco test 16CFR part 1632 and to have excellent flameproof performance and to improve the workability of the flame retardant nonwoven fabric, the halogen-containing fibers (A) and A polyester fiber (B) and / or a flame retardant cellulosic fiber (C) is obtained. The proportions of the halogen-containing fiber (A) and the polyester fiber (B) and / or the flame-retardant cellulosic fiber (C) are the above-mentioned tobacco test pass range, flameproof performance, workability of flame-retardant nonwoven fabric, and mattress material Which is determined by the bulkiness and hygroscopicity, which are requirements of the above, preferably 40 to 90% by weight of the halogen-containing fiber (A) and 10 to 60% by weight of the polyester fiber (B) and / or flame retardant cellulosic fiber (C) 0 to 50% by weight. The halogen-containing fiber (A) is a main component that exhibits self-extinguishing properties and imparts flameproof performance of the mattress. Furthermore, when the US tobacco test 16CFR part 1632 is conducted, the HCl generated from the halogen-containing fiber (A) causes the tobacco. Causes incomplete combustion, lowers the temperature of the cigarette, and prevents the heat of the cigarette from being transferred to a flammable material such as urethane foam, which is an internal structure. When A) exceeds 90% by weight, sufficient bulkiness of the nonwoven fabric cannot be obtained, and it becomes difficult to produce a flame-retardant nonwoven fabric by a thermal bond method, which is a general-purpose nonwoven fabric manufacturing method. Is not preferred. Further, if the halogen-containing fiber (A) in the flame-retardant nonwoven fabric is less than 40% by weight, it is not preferable because sufficient flameproof performance cannot be obtained. The polyester fiber (B) is a main component that imparts bulkiness to the flame retardant nonwoven fabric. However, when the proportion of the polyester fiber (B) in the flame retardant nonwoven fabric exceeds 60% by weight, sufficient flameproof performance is obtained. Since it is not possible, it is not preferable. Further, if the proportion of the polyester fiber (B) in the flame retardant nonwoven fabric is less than 10% by weight, sufficient bulkiness of the nonwoven fabric cannot be obtained, and a thermal bond which is a general-purpose nonwoven fabric manufacturing method It is not preferable that it becomes difficult to prepare a flame-retardant nonwoven fabric by the method. The flame retardant cellulosic fiber (C) forms a carbonized film at the time of combustion, and thus exhibits excellent flameproofing performance. When the flame retardant cellulosic fiber (C) in the flame retardant nonwoven fabric exceeds 50% by weight, Since the proportion of the halogen-containing fiber (A) in the flame-retardant nonwoven fabric is less than 40% by weight, the tobacco temperature is not sufficiently lowered in the tobacco test, and the heat of the tobacco is easily reduced, such as urethane foam. It is not preferable because it spreads to a flammable material and spreads, resulting in cases where it does not pass the tobacco test. When the flame retardant nonwoven fabric is composed of 40 to 90% by weight of halogen-containing fiber (A), 10 to 60% by weight of polyester fiber (B), and 0 to 50% by weight of flame retardant cellulose fiber (C), halogen-containing The proportion of the antimony compound contained in the fiber (A) is preferably 4% by weight or less. When the proportion of the antimony compound contained in the halogen-containing fiber (A) exceeds 4% by weight, when the internal structure of the mattress is a general-purpose urethane foam, an antimony compound generated from the halogen-containing fiber (A) by the heat of tobacco The effect of water generated from the flame retardant cellulosic fiber (C) is not preferable because decomposition of the urethane foam is accelerated and the US tobacco test 16CFR part 1632 may not be passed. The proportion of the three components in the flame retardant nonwoven fabric is 40 to 60% by weight of the halogen-containing fiber (A), 10 to 25% by weight of the polyester fiber (B), and 30 to 50% by weight of the flame retardant cellulose fiber (C). If the total of the three components is 100% by weight and the weight% of 25 ≧ (A)-(C) ≧ 0, it passes the US tobacco test 16CFR part 1632 and has excellent flameproofing performance. In addition, it is desirable because it improves the processability of the flame-retardant nonwoven fabric and further passes the US state of California combustion test TB603. When the weight% of (A)-(C) is ≧ 25, the formation of a carbonized film by the flame-retardant cellulose fiber (C) is not sufficient when the California Flammability Test TB603 test is performed, which is an internal structure. Since there are cases where flame retardant materials such as urethane foam ignite and do not pass the test, it is not preferable. In addition, when the weight percentage of (A)-(C) is 0, the temperature of the tobacco does not drop sufficiently in the tobacco test, and the heat of the tobacco becomes a flammable material such as urethane foam which is an internal structure. It is not preferable because the case that does not pass the cigarette test comes out because it is transmitted and spreads. When the flame retardant nonwoven fabric is composed of 40 to 90% by weight of the halogen-containing fiber (A) and 10 to 60% by weight of the polyester fiber (B), the basis weight of the flame retardant nonwoven fabric is 250 to 400 g / m ^2. Is desirable. If the basis weight of the flame retardant nonwoven fabric is less than 250 g / m ^2, it is not preferable because there may be cases where the flame test does not show sufficient flame retardant performance. Further, if the basis weight of the flame retardant nonwoven fabric is 400 g / m ² or more, high flame retardancy is exhibited, but it is difficult to say that the basis weight is economical. When the flame retardant nonwoven fabric is composed of 40 to 90% by weight of the halogen-containing fiber (A) and 10 to 60% by weight of the polyester fiber (B) and 0 to 50% by weight of the flame retardant cellulose fiber (C), The basis weight of the flame retardant nonwoven fabric is desirably 300 to 400 g / m ² . If the basis weight of the flame retardant nonwoven fabric is less than 300 g / m ² , there are cases where the flame test does not show sufficient flame retardant performance in the tobacco test. Further, if the basis weight of the flame retardant nonwoven fabric is 400 g / m ² or more, high flame retardancy is exhibited, but it is difficult to say that the basis weight is economical.

  When a mattress is produced using the flame retardant nonwoven fabric of the present invention, the excellent properties of the flame retardant nonwoven fabric of the present invention, that is, pass the US Tobacco Test 16 CFR part 1632 and have excellent flameproof performance, and processability of the nonwoven fabric. In addition, a mattress having high bulkiness, which is a requirement for a mattress material, can be obtained.

Hereinafter, the present invention will be described in more detail with reference to examples. However, the present invention is not limited to the examples.
(Production Examples 1 to 5 of halogen-containing fiber (A))
A copolymer comprising 51% by weight of acrylonitrile, 48% by weight of vinylidene chloride and 1% by weight of sodium p-styrene sulfonate (halogen content: 35% by weight) was dissolved in acetone so that the resin concentration was 30%. Antimony trioxide was added at a ratio shown in Table 1 with respect to 100 parts by weight of the resin component being dissolved in the resin to prepare a spinning dope. The spinning stock solution containing antimony trioxide was extruded into a 40% acetone aqueous solution using a nozzle having a nozzle hole diameter of 0.10 mm and a hole number of 1000 holes, washed with water, dried at 120 ° C., and then stretched three times at 150 ° C. Then, it heat-processed for 1 minute at 160 degreeC, and also the halogen-containing fiber (A) was obtained by cut | disconnecting to cut length 64mm.

(Method for creating non-woven fabric for flame retardant evaluation test)
Tetron R (fineness 6 dtex, cut) manufactured by TORAY which is a general-purpose polyester fiber as the halogen-containing fiber (A) and polyester fiber (B) prepared in Production Examples 1 to 5 of the halogen-containing fiber (A) Safmet (fineness 4.4 dtex, cut length 51 mm, melting point 110 ° C.) and flame-retardant cellulosic fiber (C) manufactured by Toray Co., Ltd., which is a heat-bonded polyester fiber (B), Sateri Visil (fineness 3.5dtex, cut length 50mm) or Lenzing FR (Lenzing FR) was used and mixed in the proportions shown in Table 2. After opening the fiber with a card, a non-woven fabric with a predetermined basis weight was prepared by a normal heat fusion method. The prepared nonwoven fabric was measured for actual basis weight and used an accurate value.

(How to make a simple mattress for flame retardant evaluation)
The flame retardancy of a flame retardant mattress was evaluated by preparing a sample of a simple mattress by the following method. The structure of a simple mattress is shown in FIGS. 2 polyurethane foams (type 360S manufactured by Toyo Rubber Industries Co., Ltd.) (1), 30 cm long x 45 cm wide x 1.9 cm thick x 1.9 cm thick, density 1.27 cm, density One sheet of 22 kg / m3 polyurethane foam (type 360S manufactured by Toyo Tire & Rubber Co., Ltd.) (2), one sheet of nonwoven fabric (3) prepared by the method for preparing a nonwoven fabric for flame retardant evaluation test, surface fabric of outer layer ( As 4), one polyester woven fabric (weighing 120 g / cm ² ) was quilted using a nylon thread (5) and a structure overlaid as shown in FIG. The quilting interval was 20 cm. This structure was sewn with a catan thread so that the distance between the hems (6) was 9 cm, and a U-shaped flame shield was created. The flame shield was cut to a length of 45 cm, wound around urethane foam, and a simple mattress for flame retardancy evaluation was created.
(Flame retardance evaluation method)
The flame-retardant performance of the flame-shielding non-woven fabrics in the examples was obtained by using a simple mattress prepared in the procedure for preparing a simple mattress for flame retardancy evaluation. (Hereinafter referred to as TB603). The US tobacco test 16CFR part 1632 test method is briefly described. A total of 18 cigarettes are placed on a mattress at intervals of 15 cm or more, and if the carbonization range is within 2 inches after the cigarette burns out, it is acceptable. To briefly explain the TB603 combustion test method in California, USA, a vertical T-shaped burner is set at 42 mm from the side of the bed, and a horizontal T-shaped burner is set at 39 mm from the top of the bed. Propane gas is used as the combustion gas, the gas pressure is 101 KPa, the upper surface has a gas flow rate of 12.9 L / min, the side surface is 6.6 L / min, the ignition time is 70 seconds on the upper surface, and 50 seconds on the side surface. The total observation time is 30 minutes. If the maximum heat release amount is less than 200 Kw and the cumulative heat release amount for the first 10 minutes is less than 25 MJ, it is acceptable.

As a criterion for evaluation of flame retardancy in the present invention, four cut cigarettes (PALL MALL) are placed in the groove portion of the simple mattress quilted prepared in the procedure of creating a simple mattress for flame retardancy evaluation, and the United States tobacco test 16 CFR. When the test was carried out by the method based on part 1632, it was spread to the internal structure even at one place, and if the carbonization range was 2 inches or more, x, and the others were marked as ◯. In addition, when tested by the method based on TB603, it spreads to the internal structure and must be forced to extinguish, or it can be applied to the top surface of the test mattress regardless of whether or not there is flame on the internal urethane. When the flame that burned moved to the side and still did not extinguish itself, it was marked as x, otherwise it was marked as o.
(Flameproof evaluation method)
The flameproofing evaluation of the flame-retardant nonwoven fabric was carried out based on JIS L1091 A-4 (vertical method) after opening the fibers mixed at a predetermined ratio with a card and making them into a twisted shape. With the holder of the oxygen index tester, the minimum oxygen concentration required for the sample to continue to burn for 5 cm was measured, and this was taken as the LOI value. As the flameproofing standard, those having a LOI value of less than 25 were evaluated as “x” and those other than that were evaluated as “◯”.
(Examples 1 to 13)
Using a nonwoven fabric created by the method for creating a flame retardant evaluation test nonwoven fabric, create a mattress based on the method for creating a simple mattress for flame retardant evaluation, and follow the flame retardant evaluation method and the flame retardant evaluation method. Evaluation and evaluation of flame resistance were carried out. The results are shown in Table 3.

(Comparative Examples 1-7)
Various fibers are mixed in the ratios shown in Table 2, simple mattresses for flame retardancy evaluation are prepared in the same manner as in Examples 1 to 13, and flame retardancy evaluation is performed according to the flame retardancy evaluation method and the flameproof evaluation method. And flameproof evaluation was carried out. The results are shown in Table 3.

  In Examples 1 to 13, in any case, when the flame retardancy evaluation test was performed by the method based on the US tobacco test 16CFR part 1632, there was almost no fire spread to the internal structure, and the carbonization range was within 2 inches, Sufficient flame retardant performance could be obtained. The LOI value was 25 or more, and the flameproof performance was good. Further, in Examples 4 to 11, in addition to passing the flame retardant evaluation test based on the US tobacco test 16CFR part 1632, the flame retardant evaluation was further performed based on the bed combustion test method Technical Bulletin 603 (hereinafter referred to as TB603) in California, USA. When implemented, the flame retardant test results were good.

  In Comparative Example 1, when the flame retardancy evaluation test was conducted by the method based on the US tobacco test 16CFR part 1632, the antimony compound contained in the halogen-containing fiber (A) exceeded 15% by weight. The antimony compound generated from the halogen-containing fiber (A) by heat promoted the decomposition of the urethane foam as the internal structure, and the carbonization range became 2 inches or more, and sufficient flame retardancy could not be obtained.

  In Comparative Example 2, when the flame retardancy evaluation test was carried out by the method based on the US tobacco test 16CFR part 1632, the basis weight of the nonwoven fabric for the flame retardancy evaluation test was small, so that the heat of tobacco changed to a general-purpose urethane foam that is an internal structure. As a result, the carbonization range was 2 inches or more, and sufficient flame retardancy could not be obtained.

  In Comparative Examples 3 and 4, when the flame retardancy evaluation test was performed by the method based on the US tobacco test 16CFR part 1632, there was almost no spread of fire to the internal structure, and the carbonization range was within 2 inches, which was sufficient for the tobacco test. Although flame retardancy could be obtained, since the proportion of the halogen-containing fiber (A) in the flame retardant nonwoven fabric is less than 40% by weight, the LOI value is less than 25, and sufficient flameproof performance can be obtained. could not.

  In Comparative Examples 5 to 7, when the flame retardancy evaluation test was performed by a method based on the US tobacco test 16CFR part 1632, the proportion of the halogen-containing fiber (A) in the flame retardant nonwoven fabric was the proportion of the flame retardant cellulosic fiber (C). The temperature of the cigarette does not drop sufficiently, and the heat of the cigarette is easily transferred to a flammable material such as urethane foam, which is an internal structure, resulting in a carbonization range of 2 inches or more and sufficient flame retardancy. I could not get sex.

Simple mattress structure for flame retardancy evaluation (overall view) Simple mattress structure for flame retardant evaluation (side view)

Claims (12)

  A mattress using a flame-retardant nonwoven fabric comprising 40 to 90% by weight of a halogen-containing fiber (A) and 10 to 60% by weight of a polyester fiber (B), and a total of cigarettes on the mattress at intervals of 15 cm or more A mattress characterized by having a carbonization range of 2 inches or less after 18 cigarettes are burned out.   A flame retardant nonwoven fabric containing 40 to 90% by weight of a halogen-containing fiber (A), 10 to 60% by weight of a polyester fiber (B), and 0 to 50% by weight of a flame retardant cellulose fiber (C). The mattress according to 1.   The mattress according to claim 2, wherein the halogen-containing fiber (A) is a flame-retardant nonwoven fabric containing 4 wt% or less of an antimony compound.   Halogen-containing fiber (A) 40-60% by weight, polyester fiber (B) 10-25% by weight, flame retardant cellulosic fiber (C) 30-50% by weight, and the total of the three components is 100% by weight The mattress according to claim 2 or 3, wherein a flame retardant non-woven fabric is used, and the weight percent of (A) ≥ weight percent of (C).   Halogen-containing fiber (A) 40-60% by weight, polyester fiber (B) 10-25% by weight, flame retardant cellulosic fiber (C) 30-50% by weight, and the total of the three components is 100% by weight A mattress using a flame retardant nonwoven fabric having a weight percentage of 0 ≧ 25 (A) − (C) ≧ 0, and a T-shaped burner perpendicular to the side of the mattress at a position of 42 mm, mattress A T-shaped burner is set horizontally at a position 39 mm from the upper surface of the propane gas, propane gas is used as the combustion gas, the gas pressure is 101 KPa, the upper surface has a gas flow rate of 12.9 L / min, the side surface has 6.6 L / min, It is characterized by a flame time of 50 seconds on the side and 70 seconds on the upper surface, a maximum heat release amount of less than 200 Kw for a total observation time of 30 minutes, and an integrated heat release amount of less than 25 MJ for the first 10 minutes. Mattress according to any one of claims 2-4 that. The mattress according to claim 1, wherein the basis weight of the flame retardant nonwoven fabric is 250 to 400 g / m ² . Mattress according to any one of claims 2-5, wherein the basis weight of the flame-retardant nonwoven fabric is 300 to 400 g / m ^2.   The halogen-containing fiber (A) is 30 to 70% by weight of acrylonitrile, 70 to 30% by weight of halogen-containing vinyl and / or halogen-containing vinylidene monomer, and 0 to 10% by weight of vinyl monomer copolymerizable therewith. The mattress according to claim 1, wherein the antimony compound is contained in an amount of 0 to 4 parts by weight with respect to 100 parts by weight of the acrylic polymer.   The mattress according to any one of claims 1 to 8, wherein the polyester fiber (B) is at least one fiber selected from the group consisting of a polyester fiber having a melting point exceeding 200 ° C and a low melting point binder fiber.   The low-melting-point binder fiber of the polyester fiber (B) is a fiber made of a single component of a low-melting polyester, a fiber made of a composite of a polyester having a melting point exceeding 200 ° C and a low-melting polyester, a polyester having a melting point exceeding 200 ° C and a low-melting polyolefin The mattress according to any one of claims 1 to 9, wherein the mattress is at least one fiber selected from the group consisting of composite fibers.   Flame retardant cellulose fiber (C) is phosphate ester compound, halogenated phosphate ester compound, condensed phosphate ester compound, polyphosphate compound, red phosphorus, amine compound, boric acid, halogen compound, bromide, A flame retardant selected from the group consisting of urea-formaldehyde compound, phosphate-urea compound and ammonium sulfate is used for cellulosic fibers selected from the group consisting of cotton, hemp, rayon, polynosic, cupra, acetate and triacetate. The mattress according to any one of claims 1 to 10, which is a fiber attached with 25% by weight. The mattress according to any one of claims 1 to 11, wherein the flame retardant cellulose fiber (C) is a rayon fiber containing 20 to 50% by weight of a flame retardant selected from silicic acid or aluminum silicate.