JP2007270411A - Flame-retardant synthetic fiber, flame-retardant fiber composite, and upholstered furniture product using the same - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide an inexpensive upholstered furniture product having good feeling and touch feeling, and useful for furniture, bedding or the like having beautiful appearance in good processability while keeping flame retardancy by solving the problems hardly solved by a conventional flame-retardant synthetic fiber. <P>SOLUTION: The flame-retardant synthetic fiber contains 3-50 pts.wt. of one or more kinds of materials (2) selected from a polyvinyl chloride, a polyvinylidene chloride, a poly(vinyl chloride-vinylidene chloride), a chlorinated polyvinyl chloride, a chlorinated paraffin, a chlorinated polyethylene, a chlorinated polyester and a chlorinated polypropylene, and 0.3-12 pts.wt. of a zinc compound, based on 100 pts.wt. of a polymer (1) including 30-70 wt.% of an acrylonitrile unit, 70-30 wt.% of a halogen-containing vinyl unit and/or a halogen-containing vinylidene unit, and 0-10 wt.% of a vinylic monomer unit copolymerizable with them. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention exhibits high flame retardancy that can be suitably used for textiles that require high flame retardancy, such as bedding and furniture, by expressing extremely high carbonization and self-extinguishing properties during combustion. The present invention relates to a flame retardant synthetic fiber, a flame retardant fiber composite, and upholstered furniture products using the same.

  In recent years, demands for ensuring the safety of clothing, food and housing have increased, and the need for flame retardant materials has increased from the viewpoint of flameproofing. Under such circumstances, in order to prevent a fire during sleeping, which causes great human damage at the time of occurrence, there is an increasing need for imparting flame retardancy to materials used for bedding and furniture.

  In products such as bedding and furniture, flammable materials such as cotton, polyester, and urethane foam are often used on the inside and the surface for comfort and design at the time of use. In order to ensure their flameproofness, the use of appropriate flame retardant materials in these products can provide a high level of flame retardancy that prevents flames from being applied to the flammable materials for a long period of time. is important. In addition, the flame retardant material must not impair the comfort and design of products such as bedding and furniture.

  Various flame retardant synthetic fibers and flame retardants have been studied in the past for the fiber products used in this flame retardant material. The high flame retardancy and comfort required for products such as bedding and furniture There has not yet been a product that fully combines requirements such as design.

  For example, there is a technique called so-called post-processing flame proofing that applies a flame retardant to cotton fabric, but there are problems such as uniform adhesion of the flame retardant, hardening of the fabric due to adhesion, detachment due to washing, and safety. It was.

  In addition, polyester fiber, which is an inexpensive material, melts when burned, so when made into a cloth alone, there is a hole and the structure cannot be maintained, and cotton or urethane used for the above-mentioned bedding, furniture, etc. The foam ignited and the performance was completely insufficient.

  In addition, there is a method to obtain highly flame-retardant modacrylic fiber by adding antimony trioxide, antimony pentoxide, tin oxide, magnesium oxide, etc. to the spinning dope. However, there is a problem that the shielding property is not sufficiently satisfied.

  Furthermore, there is a method of obtaining a highly flame-retardant fiber by using a halogen atom-containing substance such as tetrabromobisphenol A, decabromodiphenyl oxide, hexabromocyclododecane, tribromophenol, ethylenebistetrabromophthalimide as a flame retardant. Although flame retardancy can be imparted, these flame retardants have a problem that they are expensive, and there are concerns about the generation of toxic substances and the toxicity of the flame retardant itself.

  Materials that improve the defects of flame retardant fiber materials used in furniture and bedding, have excellent texture, moisture absorption, and tactile sensation required as general characteristics, and have stable flame retardant properties As a flame retardant composite, a highly flame retardant halogen-containing fiber to which a large amount of a flame retardant is added is combined with other fibers that are not flame retardant (Patent Document 1). In addition, by mixing a small amount of heat-resistant fiber, a highly flame-retardant fiber composite that can be used for work clothes, has excellent texture and moisture absorption, and has high flame resistance has been proposed. Is generally colored, the whiteness of the fabric was insufficient (Patent Document 2). Furthermore, a flame-retardant nonwoven fabric having a bulkiness from fibers that are inherently flame-retardant and halogen-containing fibers has been proposed. However, these methods require a high degree of flame retardancy unless multiple fibers are used in combination. The manufacturing process of products is complicated, and heat-resistant fibers and fibers that are inherently flame-retardant are generally expensive and disadvantageous in terms of cost (patents) Reference 3).

JP 61-89339 A JP-A-8-218259 International Publication No. 03/023108 Pamphlet

  The present invention is a problem that has been difficult to solve with conventional flame-retardant synthetic fibers, that is, inexpensive and used for furniture, bedding, etc. that have good workability, texture, and touch while ensuring flame retardancy. It aims to provide a simple textile product.

  As a result of intensive studies to solve the above problems, the present inventors have used a halogen-containing polymer in combination with a halogen-containing substance and a zinc compound, and a fiber containing the flame, while maintaining the workability, texture, and touch feeling. It has been found that a flame retardant fiber composite capable of exhibiting shielding properties and self-extinguishing properties can be obtained.

  Specifically, the flame retardant synthetic fiber (A) obtained by adding the specific substance (2) and the zinc compound together to 100 parts by weight of the specific halogen-containing polymer (1), the processability, texture, and feel. High flame retardancy as a result of combining high flame retardancy to maintain the fiber form after combustion by developing extremely high flame shielding and self-extinguishing properties during combustion without detracting from the design quality A flame retardant synthetic fiber (A) capable of obtaining a textile product used for furniture, bedding, etc., and the flame retardant synthetic fiber (A) and natural fiber and / or chemical fiber (B) It has been found that a combined flame retardant fiber composite is obtained. Moreover, it discovered that the problem of workability and a price which was a problem when using a heat-resistant fiber alone was able to be improved, and came to complete this invention.

  That is, the present invention includes 30 to 70% by weight of acrylonitrile units, 70 to 30% by weight of halogen-containing vinyl units and / or halogen-containing vinylidene units, and 0 to 10% by weight of vinyl monomer units copolymerizable therewith. From 100 parts by weight of polymer (1), from polyvinyl chloride, polyvinylidene chloride, poly (vinyl chloride-vinylidene chloride), chlorinated polyvinyl chloride, chlorinated paraffin, chlorinated polyethylene, chlorinated polyester and chlorinated polypropylene The present invention relates to a flame retardant synthetic fiber containing 3 to 50 parts by weight of one or more substances (2) selected and 0.3 to 12 parts by weight of a zinc compound.

  The substance (2) is preferably polyvinyl chloride and / or chlorinated paraffin.

  The polyvinyl chloride preferably contains 80 to 100% by weight of vinyl chloride units and 0 to 20% by weight of other copolymerizable monomer units.

  The chlorinated paraffin preferably has an average molecular weight of 300 or more and a chlorine content of 40% by weight or more.

  The zinc compound is preferably at least one selected from zinc, zinc oxide, zinc borate, zinc stannate and zinc carbonate.

  The present invention also relates to a flame retardant fiber composite containing 10% by weight or more of the flame retardant synthetic fiber (A) and 90% by weight or less of at least one kind of natural fiber and chemical fiber (B).

  As said fiber (B), it is preferable to contain 40 weight% or less of polyester fiber with respect to a flame-retardant fiber composite.

  The polyester fiber is preferably a low melting point binder fiber.

  The flame retardant fiber composite is preferably a nonwoven fabric.

  The nonwoven fabric is preferably a nonwoven fabric for flame shielding barrier.

  The present invention further relates to a upholstered furniture product using the flame retardant fiber composite.

  The flame-retardant synthetic fiber of the present invention and the upholstered furniture product obtained by using the same are excellent in design such as texture, touch, and visual feel of the fiber material itself, and have excellent workability and high flame retardancy. It is possible to do that.

  The flame-retardant synthetic fiber of the present invention comprises 3 to 50 parts by weight of the specific substance (2) and 0.3 to 12 parts by weight of the zinc compound with respect to 100 parts by weight of the specific polymer (1). Is.

  The lower limit of the preferred halogen content in the polymer (1) is 17% by weight, more preferably 20% by weight, still more preferably 26% by weight, and the upper limit is 86% by weight, more preferably 73% by weight, still more preferably 48% by weight. %. When the halogen content is less than 17% by weight, it is difficult to make the fiber flame-retardant, which is not preferable. The upper limit of 86% by weight of the halogen content corresponds to the halogen content of the vinylidene bromide homopolymer, and this value is the upper limit of the halogen content. In order to obtain a higher halogen content, it is necessary to increase the number of halogen atoms in the monomer, which is not technically practical.

  Examples of the polymer (1) include 30 to 70% by weight of acrylonitrile units, 70 to 30% by weight of halogen-containing vinyl units and 0 to 10% by weight of vinyl units copolymerizable therewith, preferably 40 to 60% by weight of acrylonitrile units. , A polymer containing 60 to 40% by weight of halogen-containing vinyl units and 0 to 10% by weight of vinyl units copolymerizable therewith. In this case, the obtained fiber has a desired performance (strength, flame retardancy, dyeability, etc.) and has an acrylic fiber texture.

  When both the halogen-containing vinyl unit and the halogen-containing vinylidene unit are included, the weight ratio thereof is preferably 90:10 to 10:90, and more preferably 70:30 to 30:70. By setting the weight ratio of the two in this range, the obtained fiber has desired performance (strength, flame retardancy, dyeability, whiteness, etc.) and can also have a texture as an acrylic fiber.

  Examples of the halogen-containing vinyl and / or halogen-containing vinylidene include halogen-containing vinyl compounds such as vinyl chloride, vinyl bromide, and vinyl fluoride, and halogen-containing vinylidene compounds such as vinylidene chloride, vinylidene bromide, and vinylidene fluoride. However, it is not limited to these. Vinyl chloride or vinylidene chloride is preferred from the viewpoint of flame retardancy, price, availability, and ease of handling of the resulting fiber.

  Examples of the vinyl monomers copolymerizable with these include acrylic acids such as acrylic acid, methyl acrylate, and butyl acrylate, and esters thereof, and methacrylic acids such as methacrylic acid, methyl methacrylate, butyl methacrylate, and the like. Amides such as esters, acrylamide and methacrylamide, vinyl acetates such as vinyl acetate and vinyl formate, vinyl sulfonic acid and its salt, methallyl sulfonic acid and its salt, styrene sulfonic acid and its salt, 2-acrylamide-2- Examples thereof include units composed of sulfonic acid group-containing monomers such as methylpropanesulfonic acid and salts thereof, and one or more of them are used. Further, at least one of them is preferably a sulfonic acid group-containing monomer because dyeability is improved.

  Specific examples of the polymer (1) include, for example, a copolymer comprising 50% by weight of vinyl chloride units, 49% by weight of acrylonitrile units, 1% by weight of sodium styrenesulfonate unit, 47% by weight of vinylidene chloride units, 51.% of acrylonitrile units. 5% by weight, copolymer comprising 1.5% by weight of sodium styrene sulfonate unit, 41% by weight of vinylidene chloride unit, 56% by weight of acrylonitrile unit, 3% by weight of sodium 2-acrylamido-2-methylpropane sulfonate unit A copolymer etc. are mentioned. This can be obtained by known polymerization methods.

  The substance (2) is at least one selected from polyvinyl chloride, polyvinylidene chloride, poly (vinyl chloride-vinylidene chloride), chlorinated polyvinyl chloride, chlorinated paraffin, chlorinated polyethylene, chlorinated polyester, and chlorinated polypropylene. is there. Among these, polyvinyl chloride and chlorinated paraffin are preferable because the safety and availability of raw materials, the price, and desired flame retardancy are easily obtained.

  The polyvinyl chloride used in the present invention preferably comprises 80 to 100% by weight of vinyl chloride units and 0 to 20% by weight of other copolymerizable monomer units, and 90 to 100% by weight of vinyl chloride units and other components. More preferably, it consists of 0 to 10% by weight of copolymerizable monomer units. Specific examples include vinyl chloride homopolymers and copolymers of vinyl chloride and other copolymerizable monomers such as vinyl acetate, acrylic acid, methyl acrylate, etc., but preferably vinyl chloride homopolymers. Polymer and copolymer of vinyl chloride monomer and vinyl acetate. These are produced by known methods. For example, a bulk polymerization method, a suspension polymerization method, an emulsion polymerization method, and a microsuspension method may be mentioned, but a resin produced by a microsuspension method is preferable, and according to this, a pretreatment such as further pulverizing the resin It can be used without.

  The chlorinated paraffin used in the present invention preferably has an average molecular weight of 300 or more and a chlorine content of 40% by weight or more, more preferably an average molecular weight of 400 or more and a chlorine content of 50% by weight or more, and an average molecular weight of 500 or more. More preferably, the chlorine content is 60% by weight or more. When the average molecular weight is less than 300 and the chlorine content is less than 40% by weight, it is difficult to obtain a sufficient amount of chlorine which is a key point of flame retardancy, and it is not preferable from the viewpoint of the safety of chlorinated paraffin. The chlorinated paraffin is manufactured by chlorinating paraffin wax or normal paraffin as a raw material.

  The substance (2) is used by being added to the polymer (1). Specific addition forms include a method of directly adding the substance (2), a method of using a masterbatch solution prepared by previously adding the substance (2) to the polymer (1) solution, or a substance (2). Examples thereof include a method in which a solution dissolved in a solvent or a plasticizer is put into a spinning solution of the polymer (1) at the time of fiberization and mixed. Of these methods, the method of adding a masterbatch solution is preferable because the mixture with the spinning solution is good and fiberization is easy.

  The amount of the substance (2) added is 3 to 50 parts by weight, preferably 5 to 20 parts by weight, based on 100 parts by weight of the polymer (1). If it is less than 3 parts by weight, it becomes difficult to obtain the desired flame retardancy, and if it exceeds 50 parts by weight, it is not preferred because there is a tendency for single yarn breakage and basic physical properties (strength, elongation, etc.) of the fiber to be inferior at the time of fiberization. .

  Examples of the zinc compound used in the present invention include, but are not limited to, zinc, zinc oxide, zinc borate, zinc stannate, and zinc carbonate. Moreover, there is no problem even if these are used in combination. The usage-amount is 0.3-12 weight part with respect to 100 weight part of polymers (1), Preferably it is 1-8 weight part, More preferably, it is 3-5 weight part. If the amount is less than 0.3 parts by weight, the effect of carbonizing the polymer (1) and the substance (2) during combustion (carbonization effect) tends to decrease, and the necessary carbonization to obtain the desired high flame resistance performance. The effect cannot be obtained. Even if it exceeds 12 parts by weight, a sufficient carbonization effect and shape retention effect can be obtained, but this is not preferable because the flexibility of the carbonized film is poor.

  The average particle size of the zinc compound is preferably 3 μm or less, and more preferably 2 μm or less. If the average particle size of the zinc compound is 3 μm or less, troubles such as nozzle clogging in the fiber production process in which the zinc compound component is added to the halogen-containing polymer are avoided, the strength of the fiber is improved, and the zinc compound in the fiber This is preferable from the viewpoint of dispersion of component particles. Although the minimum in the average particle diameter of a zinc compound is not specifically limited, 0.05 micrometer or more is preferable from the point of handling property, and 0.1 micrometer or more is more preferable. Further, the zinc compound component may be chemically modified to improve the blocking property. Examples of such chemical modification include organopolysiloxane and alumina.

The flame retardant synthetic fiber of the present invention may contain other additives such as an antistatic agent, a thermal coloring inhibitor, a light resistance improver, a whiteness improver, a devitrification inhibitor, a colorant, and a flame retardant as necessary. It may be included. Examples of flame retardants include halogen compounds such as hexabromobenzene and hexabromocyclododecane, halogen-containing phosphorus compounds such as tris (2,3-dichloropropyl) phosphate, and P compounds such as ammonium polyphosphate and dibutylaminophosphate. Mg compounds such as magnesium oxide, magnesium hydroxide, magnesium carbonate, stannic oxide, metastannic acid, stannic oxyhalide, stannous hydroxide, tin tetrachloride, ZnSnO ₃ , ZnSn (OH) ₆ , Sn compounds such as magnesium stannate, zirconium stannate and zinc hydroxystannate, Mo compounds such as molybdenum oxide, Ti compounds such as titanium oxide and barium titanate, N compounds such as melamine sulfate and guanidine sulfamate, Al such as aluminum hydroxide Onium compounds, zirconium compounds such as zirconium oxide, antimony trioxide, antimony pentoxide, although antimony compounds such as sodium antimonate and the like are not limited thereto.

  The flame-retardant synthetic fiber of the present invention may be a short fiber or a long fiber, and can be appropriately selected in the method of use. For example, it is similar to a fiber to be combined to be processed with other natural fibers and chemical fibers. It is preferable to use short fibers having a length of about 1.7 to 12 dtex and a cut length of about 38 to 128 mm in accordance with other natural fibers and chemical fibers used for textile products.

  The reason why the flame-retardant synthetic fiber of the present invention exhibits highly excellent flame retardancy is considered as follows. When the flame retardant synthetic fiber (A) containing 3 to 50 parts by weight of the substance (2) and 0.3 to 12 parts by weight of the zinc compound is burned by another flame source with respect to the polymer (1), Combustion is suppressed by the extinguishing effect of hydrochloric acid gas generated from the coalescence (1). Furthermore, hydrochloric acid gas is similarly generated from the added substance (2) to suppress combustion. Since the polymer (1) and the substance (2) are different, the temperature at which hydrochloric acid gas is generated is different. As a result, hydrochloric acid gas can be generated in a wide temperature range and has an excellent fire extinguishing ability. Further, the zinc compound reacts with hydrochloric acid gas generated during combustion, and effectively and effectively promotes the crosslinking and carbonization of the halogen-containing fiber, thereby improving the effect of maintaining the form of the fiber carbonized by combustion. Further, the substance (2) is a thermoplastic resin, and at the time of combustion, particularly in the initial stage of combustion, the resin softens and melts, and an adhesive that maintains the shape of the carbonized fiber due to the carbonization promoting effect of the zinc compound, that is, the form By exhibiting a retaining agent effect, and further covering the fiber surface, diffusion of combustible gas generated from the fiber is suppressed. Due to the combined effect of the halogen-containing polymer and the zinc compound at the time of combustion, a highly excellent flame retardancy is exhibited.

  The present invention also relates to a flame retardant fiber composite containing 10% by weight or more of the flame retardant synthetic fiber (A) and 90% by weight or less of at least one kind of natural fiber and chemical fiber (B).

  The natural fiber and / or chemical fiber (B) used in the flame retardant fiber composite of the present invention has excellent texture, touch, design, product strength, washing resistance, and durability for the flame retardant fabric of the present invention. It is a component for improving workability for giving and using a flame-retardant nonwoven fabric for bedding and furniture.

  Specific examples of the natural fibers include plant fibers such as cotton and hemp, and animal fibers such as wool, camel hair, goat wool, and silk. Specific examples of chemical fibers include, for example, regenerated fibers such as viscose rayon fiber, cupra fiber, acetate fiber, special regenerated fibers in which the regenerated fibers contain water glass (Visil registered trademark manufactured by Satellite-Oy), or nylon. Examples include, but are not limited to, synthetic fibers such as fibers, polyester fibers, polyester-based low melting point binder fibers, polypropylene fibers, polyvinyl alcohol fibers, and acrylic fibers. These natural fibers and chemical fibers may be used alone with the flame retardant synthetic fiber (A), or two or more types may be used with the flame retardant synthetic fiber (A).

  In the present invention, when the fiber (B) contains a polyester fiber, a melt is generated at the time of combustion, and the carbonized layer formed of the flame-retardant nonwoven fabric is stronger by covering the flame-retardant nonwoven fabric. Being able to provide flame-shielding barrier performance that prevents flames from being applied to cotton and urethane foam used for bedding and furniture even when exposed to intense flames for a long time, and being easy to obtain bulkiness when processed into non-woven fabrics The fiber (B) preferably contains a polyester fiber because the fiber (A) relaxes the fiber (A) due to the strength problem of the fiber (A). In this case, the content of the polyester fiber is preferably 40% by weight or less, more preferably 15 to 25% by weight, based on the flame retardant fiber composite.

  When a polyester-based low-melting-point binder fiber is used, a simple hot-melt bonding method can be adopted when forming a nonwoven fabric. The polyester-based low-melting-point binder fiber may be a low-melting-point polyester single-type fiber or a parallel-type or core-sheath-type composite fiber made of polyester / low-melting-point polypropylene, low-melting-point polyethylene, or low-melting-point polyester. 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. In addition, when a polyester fiber having a low melting point is used, a simple needle punch method can be employed when forming a nonwoven fabric.

  In the present invention, the flame-retardant fabric of the present invention is produced from 10% by weight or more of the flame-retardant synthetic fiber (A) and 90% by weight or less of the natural fiber and / or chemical fiber (B). Proportion is the quality of water absorption, texture, moisture absorption, touch, design, product strength, washing resistance, durability, etc., as well as the flame resistance required for the final product manufactured from the resulting flame retardant nonwoven fabric It is decided according to. Generally, the flame retardant synthetic fiber (A) is 90 to 10% by weight, preferably 60 to 20% by weight, and the natural fiber and / or chemical fiber (B) is 10 to 90% by weight, preferably 80 to 40% by weight. Can be combined. When the hot melt bonding method is selected during the production of the nonwoven fabric, it is preferable that the polyester-based low-melting-point binder fiber is contained at least 10% by weight as the natural fiber and / or chemical fiber (B) with respect to the flame retardant fiber composite. .

  When the amount of the flame retardant synthetic fiber (A) is less than 10% by weight, a carbonized layer is formed to prevent flames from being applied to cotton and urethane foam used for bedding and furniture when exposed to intense flames for a long time. Insufficient and difficult to obtain the desired high flame retardant performance. On the other hand, when the amount of the flame retardant synthetic fiber (A) exceeds 90% by weight, that is, when the polyester-based low-melting-point binder fiber is less than 10% by weight, the hot-melt adhesiveness is insufficient, and the strength of the obtained nonwoven fabric Tends to be reduced, resulting in a decrease in workability.

  The flame-retardant fiber composite of the present invention is a composite of the fibers (A) and (B) as described above, and is a fabric knitted fabric, a fabric such as a nonwoven fabric, a collection of fibers such as a sliver and a web, a spun yarn and a composite. It is in the form of a string-like material such as a thread or twisted yarn, a string-like material such as a braided string or a braided string.

  The composite means that the fibers (A) and (B) are mixed by various methods to obtain a cloth containing the fibers in a predetermined ratio, and each of the mixed cotton, spinning, twisting, weaving and knitting stages. It means combining fiber and yarn.

  The flame retardant fiber composite of the present invention is suitably used as a nonwoven fabric for flame shielding barriers. The flame-shielding barrier here means that when the flame-retardant nonwoven fabric is exposed to flame, the flame-retardant nonwoven fabric is carbonized while maintaining the fiber form to shield the flame, and the flame moves to the opposite side. Specifically, in the event of a fire, the flame-retardant nonwoven fabric of the present invention is sandwiched between a surface fabric such as a mattress or upholstered furniture and an internal structure such as urethane foam or stuffed cotton. This prevents flames from igniting internal structures and minimizes damage. Non-woven fabric production methods such as general hot melt bonding, chemical bonding, water jet, needle punching, stitch bonding, etc. can be used as a method for producing a flame retardant nonwoven fabric. After the cotton is blended, it is opened by a card, a web is produced, and the web is applied to a nonwoven fabric production apparatus. From the viewpoint of simplicity of the apparatus, it is preferable to use a needle punch method or a polyester-based low-melting-point binder fiber because the production by the hot melt bonding method is general and the productivity is high, but it is not limited thereto.

  The flame retardant fiber composite of the present invention may contain an antistatic agent, a thermal coloring inhibitor, a light fastness improver, a whiteness improver, a devitrification preventive agent, and the like as necessary. There is no problem with coloring or dyeing with pigments.

  The flame retardant fiber composite of the present invention thus obtained has desired flame retardancy and has excellent properties such as texture, touch, hygroscopicity, and design.

  The upholstered furniture of the present invention relates to bedding such as a bed mattress, a chair, a sofa, a vehicle seat, and the like upholstered by the above-mentioned flame-retardant fiber composite.

  Examples of the bed mattress include a pocket coil mattress in which a metal coil is used, a box coil mattress, a mattress in which an insulator in which styrene, urethane resin, or the like is foamed is used. Since the flame retardancy of the flame retardant composite used in the present invention is exhibited, it is possible to prevent the spread of fire to the structure inside the mattress. A mattress excellent in texture and touch can be obtained.

  On the other hand, as chairs used indoors, tools, benches, side chairs, armchairs, lounge chairs and sofas, seat units (sectional chairs, separate chairs), rocking chairs, folding chairs, stacking chairs, swivel chairs, Or automobile seats, marine seats, aircraft seats, train seats, etc., used outdoors for vehicle seats, etc., but also in these, the internal fire spreads at the same time as the appearance and feel required for normal furniture It is possible to obtain a upholstered product having a function of preventing the above.

  For mattresses and chairs that use low-resilience urethane foam with pressure dispersion function, such as Tempur World (Tempur World, Inc. registered trademark) Although it is extremely flammable compared to mattresses and chairs using materials, the flame retardant fiber composite used in the present invention exhibits low flame resistance, which is the inner structure of mattresses and chairs. Can spread fire to rebound urethane foam.

  As a method of using the flame-retardant fiber composite of the present invention for upholstered furniture products, the surface fabric may be used in the form of woven fabric or knit, or the surface fabric and internal structure such as urethane foam or stuffed cotton. It may be sandwiched in the form of woven fabric, knit or non-woven fabric. When used for the surface fabric, the fabric made of the flame retardant fiber composite of the present invention may be used instead of the conventional surface fabric. In addition, when a woven fabric or a knit is sandwiched between the surface fabric and the internal structure, the surface fabric may be sandwiched in the manner of overlapping two sheets, or the internal structure is a woven fabric made of the flame retardant fiber composite of the present invention. Or it may be covered with knit. When sandwiched between the surface fabric and the internal structure as a woven fabric for a flame-shielding barrier, the flame retardant fiber of the present invention must be placed on the entire internal structure, and at least the portion in contact with the surface fabric outside the internal structure. A non-woven fabric made of a composite is covered, and the surface fabric is stretched over it.

  When producing upholstered furniture using the flame retardant fiber composite of the present invention, the flame retardant fiber composite of the present invention has excellent characteristics, that is, highly excellent flame retardancy, texture, touch, and moisture absorption. Thus, a upholstered furniture product having excellent design characteristics can be obtained.

  EXAMPLES Hereinafter, although an Example is given and this invention is demonstrated in more detail, this invention is not limited only to this Example.

Production Example 1
As polymer (1), 100 parts of a polymer (halogen content 35% by weight) consisting of 51% acrylonitrile units, 48% vinylidene chloride units and 1% p-styrene sulfonic acid soda units, the resin concentration becomes 30%. A predetermined amount of polyvinyl chloride resin (vinyl chloride paste resin PSH-10 manufactured by Kaneka Corporation) or chlorinated paraffin (Ajinomoto Fine Techno Co., Ltd.) shown in Table 1 as a substance (2) dissolved in acetone. Made of ENPARA 70 (average molecular weight 1156, chlorine content 70%)), and a predetermined amount of zinc oxide (3 types of zinc oxide manufactured by Sakai Chemical Co., Ltd.) shown in Table 1 were added as a zinc compound to prepare a spinning dope.

  The spinning dope was extruded into a 30% aqueous acetone solution at 25 ° C. using a nozzle with a nozzle hole diameter of 0.10 mm and a hole number of 1000 holes, washed with water, dried at 140 ° C., then stretched 2.5 times, and further A halogen-containing fiber was obtained by performing a heat treatment at 150 ° C. for 3 minutes and then cutting. The obtained fiber was a short fiber having a fineness of 7.8 dtex and a cut length of 64 mm.

Production Example 2
As the polymer (1), a polymer composed of 49% by weight of acrylonitrile unit, 25% by weight of vinyl chloride unit, 25% by weight of vinylidene chloride unit and 1% by weight of sodium p-styrene sulfonate unit (halogen content 33% by weight) 100 A part is dissolved in acetone so that the resin concentration becomes 30% by weight, and a predetermined amount of chlorinated paraffin (Empara 70 (average molecular weight 1156, manufactured by Ajinomoto Fine Techno Co., Ltd.) shown in Table 1 is used as the substance (2) in this solution. Chlorine content 70% by weight)), and a predetermined amount of zinc oxide (3 types of zinc oxide manufactured by Sakai Chemical Co., Ltd.) shown in Table 1 was added as a zinc compound to prepare a spinning dope. Thereafter, a halogen-containing fiber having a fineness of 7.8 dtex and a cut length of 64 mm was obtained in the same manner as in Production Example 1.

Examples 1 to 6 and Comparative Example 1
The flame retardancy of the flame retardant synthetic fibers in Examples 1 to 6 and Comparative Example 1 was evaluated using the fiber alone as follows.

<Flame retardancy evaluation method 1 (Flame retardance assessment by LOI value)>
Take 2g of flame retardant synthetic fiber produced according to the above production example, divide this into 8 parts, produce 8 pieces of about 6cm twist, and stand upright on the holder of an oxygen index measuring instrument (ON-1 type manufactured by Suga Test Instruments) The minimum oxygen concentration required for this sample to continue to burn for 5 cm was measured, and this was defined as the LOI value. It shows that it is hard to burn, so that a flame retardance is high, so that LOI value is large.

  According to the production examples 1 and 2, a flame retardant synthetic fiber (A) in which vinyl chloride resin or chlorinated paraffin as the substance (2) and zinc oxide as the zinc compound were added in the ratios shown in Table 1 was prepared, and the LOI value was determined. Flame retardant evaluation was performed. The results are shown in Table 1.

  It can be seen from Table 1 that Examples 1 to 6 are excellent in numerical values in the flame retardancy evaluation based on the LOI value. On the other hand, since Comparative Example 1 did not contain the substance (2) and the zinc compound, the LOI value was low and inferior.

Examples 7-20 and Comparative Examples 2-5
The flame retardancy of the flame retardant fiber composites in the examples was evaluated by the following flame retardancy evaluation method 2.

  Flame retardant evaluation method 2 is a method in which the flame retardant nonwoven fabric of the present invention is sandwiched between surface fabrics such as upholstered furniture such as bed mattresses, chairs, sofas, etc., and urethane foam or stuffed cotton which is an internal structure. This is a simple evaluation method based on the image of preventing the ignition of internal structures in the event of a fire. The pass / fail judgment of the evaluation results was performed as follows.

  Comprehensive evaluation is performed based on the evaluation results of flame retardancy and workability. If both flame retardance and workability are ◎ or ○, the overall evaluation is passed ○, and either flame retardancy or workability When there was a determination of ×, the comprehensive evaluation was determined to be rejected ×.

<Flame retardancy evaluation method 2>
1) Preparation of non-woven fabric for flame retardancy evaluation test Fibers mixed at a predetermined ratio are opened with a card, and then a non-woven fabric having a basis weight of 300 g / m ² , 20 cm in length and 20 cm in width is produced by a needle punch method. It was set as the nonwoven fabric for a property evaluation test.

2) Flame Retardancy Evaluation Test Method Prepare a pearlite plate with a length of 200 mm x width 200 mm x thickness 10 mm with a hole with a diameter of 15 cm, set a non-woven fabric for flame retardant evaluation test on it, and heat At times, the four sides were fixed with clips so that the nonwoven fabric for flame retardancy evaluation test did not shrink. Set this sample with the non-woven fabric for flame retardancy evaluation test facing up, and set it on a gas stove (PA-10H-2) manufactured by Paloma Industry Co., Ltd. so that the center of the sample is aligned with the center of the burner at 40 mm from the burner surface. did. Propane with a purity of 99% or more was used as the fuel gas, the flame height was 25 mm, the flame time was 180 seconds, and the physical properties were evaluated according to the following evaluation criteria. In addition, (double-circle) or (circle) is a pass.
A: There is no unevenness in the thickness of the carbonized film of the nonwoven fabric for flame retardancy evaluation test, and there are no holes or cracks. O: There are uneven spots in the thickness of the carbonized film, but there are no holes or cracks.

3) Processability evaluation About the card | curd permeability (ease of process) at the time of this nonwoven fabric preparation, the physical property was evaluated by the following evaluation criteria. In addition, (double-circle) or (circle) is a pass.
◎: When it is good ○: When possible ×: When it is difficult for cotton to fall

  Flame retardant synthetic fiber (A) to which vinyl chloride resin or chlorinated paraffin is added as the substance (2) prepared according to the above production examples 1 and 2 and zinc oxide is added as a zinc compound in the ratio shown in Table 2, natural fiber and / or Alternatively, it is difficult to use a non-woven fabric in which rayon fiber (1.7 dtex, cut length 38 mm) and polyester fiber (4.4 dtex, cut length 51 mm) are mixed at a predetermined ratio as at least one kind of fiber (B) among chemical fibers. A non-woven fabric for flame retardancy evaluation test of Flammability Evaluation Method 2 was prepared and flame retardancy was evaluated. The results are shown in Table 2.

  The combustion test results of Examples 7 to 18 were good, and the non-woven fabric for flame retardancy evaluation test had no cracks or holes after heating with a gas stove and formed a good carbonized film. Moreover, the workability was also good. On the other hand, although Comparative Examples 2-4 had good workability, since the amount of zinc oxide added was large, the flexibility of the carbonized film was lost and cracking occurred. In Comparative Example 5, since the amount of the substance (2) added was large, the basic physical properties of the fiber were inferior, and the strength of the carbonized film could not be obtained. In Example 19, since the proportion of the halogen-containing fiber is 100%, the flame retardancy is good, but since the natural fiber and / or the chemical fiber (B) is not included, the card falls off during the production of the nonwoven fabric. There was a problem of workability. In Example 20, a good carbonized film was not formed with a small proportion of halogen-containing fibers.

Examples 21-32
The upholstered furniture products in Examples 21 to 32 were evaluated by the flame retardancy evaluation method 3 and the flame retardance evaluation method 4. In the event of a fire, the flame retardant nonwoven fabric of the present invention is sandwiched between surface fabrics such as upholstered furniture such as bed mattresses, chairs, sofas, etc. and urethane foam or stuffed cotton that is an internal structure. This is a simple evaluation method based on the image of preventing the ignition of internal structures. The pass / fail judgment of the evaluation results was performed as follows.

  If the flame retardant evaluation method 3 is ◎ or ○, and the flame retardant evaluation method 4 is ◯ or △, the overall evaluation is a pass ○. In the judgment, it was judged as “failed x”. The detailed determination method is described below.

<Flame retardance evaluation method 3>
1) Preparation and Evaluation Method of Sample for Simple TB603 Flame Retardancy Evaluation Test The flame retardancy of a flame retardant mattress was evaluated by preparing a sample of the simple mattress by the following method. A cross-sectional structure of a simple mattress is shown in FIG. 2 sheets of polyurethane foam (1) (type 360S manufactured by Toyo Tire & Rubber Co., Ltd.) having a length of 30 cm × width of 45 cm × thickness of 1.9 cm and a density of 22 kg / m ^{3 at} a predetermined ratio as a nonwoven fabric for flame retardant evaluation test After opening the mixed fiber with a card, weaving polyester as a surface fabric (3) for the outer layer (3), one piece of non-woven fabric (2) prepared with a basis weight of 300 g / cm ² , 30 cm long x 45 cm wide One piece of cloth (weighing 120 g / cm ² ) and a structure overlaid as shown in FIG. 2 were quilted using nylon thread (4). The quilting interval was 20 cm. This structure was sewn with a catan thread so that the hem spacing was 9 cm, and a U-shaped flame shield was produced. The flame shield was cut to a length of 45 cm, wound around urethane foam, and a simple mattress for flame retardancy evaluation was produced.

This flame retardant evaluation test sample was subjected to flame retardant evaluation according to the bed upper surface test method in the bed flame test method Technical Bulletin 603 of California, USA. That is, a T-shaped burner is set horizontally at a position 39 mm from the upper surface of the sample, and propane gas is used as a combustion gas, and the indirect flame is performed for 70 seconds under the conditions of a gas pressure of 101 KPa and a gas flow rate of 12.9 L / min. The physical properties were evaluated according to the evaluation criteria. In addition, (double-circle) or (circle) is a pass.
◎: There is no thickness unevenness on the carbonized film of the nonwoven fabric, and there are no holes or cracks. ○: There is a thickness unevenness on the carbonized film but there are no holes or cracks.

<Flame retardance evaluation method 4>
1) Preparation and Evaluation Method of Sample for Simple 16CFR part 1632 Flame Retardancy Evaluation Test A sample was prepared for a simple mattress by the following method and evaluated. The structure of a simple mattress is shown in FIGS. The fibers mixed at a predetermined ratio were opened with a card, and then a non-woven fabric having a basis weight of 400 g / m ² and a length of 30 cm × width of 30 cm was prepared by a heat fusion method. This is placed on urethane (5), (6) (Achilles Corporation density 18 kg / m ³ ) having a length of 30 cm × width of 30 cm × thickness of 5 cm, and further a cotton woven fabric (weight per unit: 120 g / cm ² ) as surface fabric (8). ) Wrapped the entire surface of the nonwoven fabric (7), urethane (5), (6), and then quilted the diagonal on the front side with an industrial quilt sewing machine (manufactured by Juki Co., Ltd.) to give a pseudo mattress. Four ignited cigarettes were placed on the quilt portion (9) of the pseudo mattress, and the test was started. The physical properties of the simulated mattress after the test were evaluated according to the following evaluation criteria in accordance with US Federal Law 16CFR part 1632. In addition, (circle) or (triangle | delta) was set as the pass.
○: The surface carbonized range is within 2 inches from the tobacco, and the carbonized portion is not exposed on the back surface. Δ: The surface carbonized range is within 2 inches from the tobacco, and the carbonized portion is exposed on the back surface. More than 2 inches from

  Flame retardant synthetic fiber (A) to which vinyl chloride resin or zinc oxide as a chlorinated paraffin and zinc compound is added in the ratio shown in Table 3 as a substance (2) prepared according to the above production example, natural fiber and / or chemical fiber Flame retardant evaluation using a non-woven fabric in which rayon fibers (1.7 dtex, cut length 38 mm) and polyester fibers (4.4 dtex, cut length 51 mm) are mixed at a predetermined ratio as at least one kind of fibers (B) A nonwoven fabric for flame retardancy evaluation test of Method 3 and Flame retardance evaluation method 4 was prepared, a simple evaluation sample was prepared, and flame retardance evaluation was performed by each flame retardancy evaluation method. The results are shown in Table 3.

  From Table 3, the flame retardancy test results of Examples 21 to 28 were good, a good carbonized film was formed, and no flame was found on the urethane foam. On the other hand, in Examples 29 to 30, since a large amount of zinc oxide is added, the flexibility of the carbonized film is lost and cracking occurs. Although it was rejected, it was acceptable because it contained the substance (2) that exhibited an excellent effect in the simple 16CFR part 1632 flame retardancy evaluation test, but it was rejected in the comprehensive evaluation. In Example 31, since the proportion of the halogen-containing fiber was 100%, the simple 16CFR part 1632 flame retardant evaluation test was passed due to the effect of the halogen-containing fiber, but in the simple TB603 flame retardant evaluation test, the form of the carbonized film Because it does not contain natural fibers and / or chemical fibers (B) for improving the quality of the resin, it cracks the carbonized film due to the gas pressure of the burner flame, and fails due to flame formation on the urethane foam. Since there was a problem of workability such as dropping out of the card at the time of production, the overall evaluation was also rejected. In Example 32, it passes because it contains the substance (2) that exhibits an excellent effect in the simple 16CFR part 1632 flame retardancy evaluation test, but because the amount of addition is large, the basic physical properties of the fiber are poor and the strength of the carbonized film is obtained. Therefore, in the simple TB603 flame retardant evaluation test, the carbonized film was cracked by the gas pressure of the burner flame, and it was rejected due to the flame on the urethane foam, and the overall evaluation was also rejected.

It is a structure (cross-sectional view) of a simple mattress for simple TB603 flame retardancy evaluation. It is a structure (overall view) of a simple mattress for simple 16CFR part 1632 flame retardance evaluation. It is a structure (cross-sectional view) of a simple mattress for flame retardant evaluation of simple 16 CFR part 1632.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Polyurethane foam 2 Nonwoven fabric 3 Surface fabric 4 Nylon thread 5, 6 Urethane 7 Nonwoven fabric 8 Surface fabric 9 Quilt part 10 Base material

Claims (11)

Polymer (1) containing 30 to 70% by weight of acrylonitrile units, 70 to 30% by weight of halogen-containing vinyl units and / or halogen-containing vinylidene units, and 0 to 10% by weight of vinyl monomer units copolymerizable therewith One or more kinds selected from polyvinyl chloride, polyvinylidene chloride, poly (vinyl chloride-vinylidene chloride), chlorinated polyvinyl chloride, chlorinated paraffin, chlorinated polyethylene, chlorinated polyester and chlorinated polypropylene per 100 parts by weight A flame-retardant synthetic fiber containing 3 to 50 parts by weight of the substance (2) and 0.3 to 12 parts by weight of a zinc compound. The flame retardant synthetic fiber according to claim 1, wherein the substance (2) is polyvinyl chloride and / or chlorinated paraffin. The flame retardant synthetic fiber according to claim 2, wherein the polyvinyl chloride contains 80 to 100% by weight of vinyl chloride units and 0 to 20% by weight of other copolymerizable monomer units. The flame-retardant synthetic fiber according to claim 2, wherein the chlorinated paraffin has an average molecular weight of 300 or more and a chlorine content of 40% by weight or more. The flame-retardant synthetic fiber according to claim 1, wherein the zinc compound is at least one selected from zinc, zinc oxide, zinc borate, zinc stannate and zinc carbonate. A flame retardant composition comprising 10% by weight or more of the flame retardant synthetic fiber (A) according to claim 1, 2, 3, 4 or 5, and 90% by weight or less of at least one kind of natural fiber and chemical fiber (B). Fiber composite. The flame retardant fiber composite according to claim 6, wherein the fiber (B) contains a polyester fiber in an amount of 40% by weight or less based on the flame retardant fiber composite. The flame-retardant fiber composite according to claim 7, wherein the polyester fiber is a low-melting-point binder fiber. The flame retardant fiber composite according to claim 6, 7 or 8, wherein the flame retardant fiber composite is a nonwoven fabric. The flame retardant fiber composite according to claim 9, wherein the nonwoven fabric is a nonwoven fabric for a flame shielding barrier. A upholstered furniture product using the flame retardant fiber composite according to claim 6, 7, 8, 9 or 10.

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