JP2007308849A - Flame-retardant synthetic fiber, frame-retardant fiber composite material and upholstered furniture using the same - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a flame-retardant synthetic fiber and a flame-retardant fiber composite material suitable for a textile product to be used for bedding, furniture, etc., necessitating high flame-retardancy, by highly improving the carbonization property in combustion with an additive and provide upholstered furniture produced by using the fiber, etc. <P>SOLUTION: The flame-retardant synthetic fiber comprises 100 pts.wt. of a polymer containing ≥17 wt.% halogen atom, 5-30 pts.wt. of cellulose acetate and 5-35 pts.wt. of a glassy substance, provided that the sum of the cellulose acetate and the glassy substance is 10-40 pts.wt. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention provides a flame-retardant synthetic fiber and a flame-retardant fiber composite that can be suitably used for textiles that require a high degree of flame retardancy, such as bedding and furniture, by expressing extremely high carbonization during combustion. And upholstered furniture products using the same.

  In recent years, there has been an increasing demand for ensuring safety in clothing, food and housing, and flame retardant materials from the standpoint of flame prevention, especially for materials used for bedding and furniture to prevent fires during sleep, which can cause significant human damage. The need for imparting flammability is increasing.

  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.

  Polyester fiber, which is an inexpensive material, melts when burned, so when it is made into a fabric, there is a hole and the structure cannot be maintained, and it can be worn on cotton or urethane foam used in the above-mentioned bedding and furniture. The flame was burnt out, and the performance was totally 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. On the other hand, there was a problem that the shielding performance was not satisfactory.

  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, highly flame retardant fiber composites that can be used for work clothes by mixing a small amount of heat resistant fiber, have excellent texture and moisture absorption, and have high flame resistance have been proposed. Since the fibers are generally colored, the whiteness of the fabric was insufficient (Patent Document 2). Furthermore, they have also proposed bulky flame retardant nonwoven fabrics that are essentially flame retardant fibers and halogen-containing fibers. However, these methods require advanced use of multiple fibers in combination. Flame retardancy is not obtained, the manufacturing process of the product is complicated, and heat-resistant fibers and fibers that are inherently flame-retardant are generally expensive and disadvantageous in terms of cost. (Patent Document 3). There are also flame-retardant polyester materials that are made flame-retardant with a glass material, but since the amount of glass material is remarkably large, there are problems with high cost and process stability during fiberization (Patent Document 4). Furthermore, a highly flame retardant acrylic fiber containing a polymer containing at least 50% by weight of a monomer having at least one hydroxyl group in a monomer unit represented by polyvinyl alcohol and antimony pentoxide has also been proposed. However, antimony pentoxide is an essential component and does not correspond to the recent repelling movement of antimony, and there are many restrictions such as limiting the particle size of antimony pentoxide in the fiber (patent document) 5).

JP 61-89339 A JP-A-8-218259 International Publication No. 03/023108 Pamphlet Japanese Patent Laid-Open No. 9-278999 Japanese Patent No. 3370395

  The present invention is a problem that has been difficult to solve with conventional flame-retardant synthetic fibers, that is, fibers used in furniture, bedding, etc. that have good workability, texture, and touch while ensuring flame retardancy. It was made to make it possible to manufacture products at low cost.

  As a result of intensive studies to solve the above problems, the inventors of the present invention have used a fiber in which cellulose acetate and / or a glass substance is added to a halogen atom-containing polymer, while maintaining workability, texture, and touch, while maintaining flame. It has been found that flame retardancy having a shielding property of is obtained. Moreover, it discovered that the glass material which was a subject can also be reduced by the combined use with cellulose acetate.

  Specifically, the flame-retardant synthetic fiber obtained by adding cellulose acetate and / or glass material to a polymer containing 17% by weight or more of halogen atoms has good workability, texture, and touch without sacrificing design. It has been found that it exhibits extremely high flame shielding and self-extinguishing properties during combustion. Thus, as a result of having high flame retardancy that maintains the fiber form after combustion, it is possible to obtain a flame retardant composition that can be used for furniture, bedding, etc. that require high flame retardance. It has been found that a flame retardant fiber composite obtained by combining the fiber (A) and at least one kind of fiber (B) of natural fiber and chemical fiber 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, in the present invention, 5 to 30 parts by weight of cellulose acetate, 5 to 35 parts by weight of a glass substance, and a total of the cellulose acetate and the glass substance with respect to 100 parts by weight of a polymer containing 17% by weight or more of halogen atoms. The present invention relates to a flame retardant synthetic fiber to be contained in an amount of 10 to 40 parts by weight.

  The polymer containing 17% by weight or more of the halogen atom contains 30 to 70% by weight of acrylonitrile units, 70 to 30% by weight of halogen-containing vinyl monomer units and / or halogen-containing vinylidene monomer units, and It preferably contains 0 to 10% by weight of a polymerizable vinyl monomer unit.

  The cellulose acetate is preferably diacetyl cellulose and / or triacetyl cellulose.

  The glass material preferably has a glass transition temperature of 200 to 700 ° C.

The glass material is SiO ₂ —PbO, SiO ₂ —PbO—ZnO, SiO ₂ —B ₂ O ₃ —Na ₂ O, SiO ₂ —B ₂ O ₃ —PbO, SiO ₂ —Al ₂ O _3. , B ₂ O ₃ —PbO, B ₂ O ₃ —ZnO, B ₂ O ₃ —Na ₂ O—PbO, B ₂ O ₃ —PbO—ZnO, B ₂ O ₃ —P ₂ O ₅ , B ₂ O ₃ —Bi ₂ O ₃ —ZnO and P ₂ O ₅ —ZnO are preferred.

  The present invention also includes (A) 10% by weight or more of the flame retardant synthetic fiber according to any one of claims 1 to 5, and (B) 90% by weight or less of at least one kind of natural fiber and chemical fiber. Also related to flame retardant fiber composites.

  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 using the same are excellent in design properties such as texture, touch, and visual feel of the fiber material itself and processability, and are highly difficult. It is possible to have flammability.

  In the present invention, 5 to 30 parts by weight of cellulose acetate, 5 to 35 parts by weight of glass material, and 10 to the total of cellulose acetate and glass material with respect to 100 parts by weight of a polymer containing 17% by weight or more of halogen atoms. It is a flame retardant synthetic fiber contained so as to be ˜40 parts by weight.

  The lower limit of the halogen content in the polymer containing 17% or more of halogen atoms in the present invention is preferably 20% by weight, more preferably 26% by weight. On the other hand, as an upper limit, Preferably it is 86 weight%, More preferably, it is 73 weight%, More preferably, it is 48 weight% or less. 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 the halogen content is 86% by weight, which is 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 containing 17% by weight or more of halogen atoms as described above include a polymer of a monomer containing a halogen atom, and a copolymer of a monomer containing a halogen atom and a monomer not containing a halogen atom. Polymer, a mixture of a polymer containing a halogen atom and a polymer not containing a halogen atom, a halogen atom-containing monomer or a polymer containing a halogen atom introduced during or after polymerization Examples include, but are not limited to, polymers.

  Specific examples of such a polymer containing 17% by weight or more of halogen atoms include halogen-containing vinyl-based or vinylidene-based polymers such as vinyl chloride, vinylidene chloride, vinyl bromide, vinylidene bromide, vinyl fluoride, vinylidene fluoride, and the like. Monomer homopolymer or two or more copolymers; acrylonitrile-vinyl chloride, acrylonitrile-vinylidene chloride, acrylonitrile-vinyl bromide, acrylonitrile-vinyl fluoride, acrylonitrile-vinyl chloride-vinylidene chloride, acrylonitrile-vinyl chloride -Copolymers of vinyl bromide, acrylonitrile-vinylidene chloride-vinyl bromide, acrylonitrile-vinylidene chloride-vinylidene fluoride and other halogen-containing vinyl or vinylidene monomers and acrylonitrile; vinyl chloride, vinylidene chloride Copolymers of one or more halogen-containing vinyl-based or vinylidene-based monomers such as vinyl bromide, vinylidene bromide, vinyl fluoride, and vinylidene fluoride with acrylonitrile and vinyl monomers copolymerizable therewith A polymer obtained by adding and polymerizing a halogen-containing compound to an acrylonitrile homopolymer; a halogen-containing polyester; a copolymer of vinyl alcohol and vinyl chloride; a polymer obtained by chlorination treatment of polyethylene, polyvinyl chloride, or the like. However, it is not limited to these. Moreover, you may use the said homopolymer and copolymer suitably mixing.

  The polymer containing 17% by weight or more of halogen is 30 to 70% by weight of acrylonitrile units, 70 to 30% by weight of halogen-containing vinyl monomer units and / or halogen-containing vinylidene monomer units, and copolymerized therewith. It is preferable to contain 0 to 10% by weight of a possible vinyl monomer unit, 40 to 60% by weight of an acrylonitrile unit, 60 to 40% by weight of a halogen-containing vinyl monomer unit and a vinyl monomer copolymerizable therewith. A polymer containing 0 to 10% by weight of a monomer unit is more preferable. In this case, the obtained fiber has a desired performance (strength, flame retardancy, dyeability, etc.) and has a texture of acrylic fiber, which is particularly preferable.

  Examples of the copolymerizable vinyl monomer include acrylic acid such as acrylic acid, methyl acrylate, and butyl acrylate and esters thereof, methacrylic acid such as methacrylic acid, methyl methacrylate, and butyl methacrylate and esters thereof, Amides such as 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-acrylamido-2-methylpropane Examples thereof include sulfonic acid group-containing monomers such as sulfonic 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 containing 17% by weight or more of the halogen include, for example, a copolymer comprising 50% by weight of vinyl chloride units, 49% by weight of acrylonitrile units, and 1% by weight of sodium styrenesulfonate unit, and 47% by weight of vinylidene chloride units. A copolymer consisting of 51.5% by weight of acrylonitrile units and 1.5% by weight of sodium styrene sulfonate unit, 41% by weight of vinylidene chloride units, 56% by weight of acrylonitrile units, sodium 2-acrylamido-2-methylpropane sulfonate unit Examples thereof include a copolymer comprising 3% by weight. These can be obtained by known polymerization methods.

  Examples of cellulose acetate used in the present invention include diacetyl cellulose and triacetyl cellulose. The acetylation degree of cellulose acetate is preferably 45 to 62%, and the polymerization degree is 100 to 200 from the viewpoint of easy availability of cellulose acetate and obtaining an appropriate spinning dope viscosity during fiber production.

The glass substance used in the present invention has a glass transition temperature of 200 to 700 ° C., preferably 200 to 400 ° C., and is SiO ₂ —PbO-based, SiO ₂ —PbO—ZnO-based, SiO ₂ —B ₂ O _3. -Na ₂ O-based, SiO ₂ -B ₂ O ₃ -PbO based, SiO ₂ -Al ₂ O ₃ system, B ₂ O ₃ -PbO based, B ₂ O ₃ -ZnO system, B ₂ O ₃ -Na ₂ O -PbO system, B ₂ O _{3 -PbO-ZnO-based, B 2 O 3 -P 2 O} 5 _{based, B 2 O 3 -Bi 2 O} 3 -ZnO system, and at least selected from P ₂ O ₅ -ZnO system It is a kind. Among these, from the viewpoint of ensuring safety, versatility, and desired flame retardance during combustion, SiO ₂ —B ₂ O ₃ —Na ₂ O, SiO ₂ —Al ₂ O ₃ , B ₂ O ₃ — It is preferable to use a ZnO system, a B ₂ O ₃ —P ₂ O ₅ system, a B ₂ O ₃ —Bi ₂ O ₃ —ZnO system, a P ₂ O ₅ —ZnO system, and a B ₂ O ₃ —ZnO system, B It is more preferable to use a ₂ O ₃ —P ₂ O ₅ system or a P ₂ O ₅ —ZnO system. When the glass transition temperature is less than 200 ° C., the melting at the time of combustion is fast, and when it exceeds 700 ° C., it does not melt at the time of combustion, and thus it tends to be difficult to obtain desired flame retardancy.

  These cellulose acetate and glass substance are added in an amount of 5 to 30 parts by weight of cellulose acetate, 5 to 35 parts by weight of glass substance, and 100 to 50 parts by weight of the polymer containing 100% by weight of a halogen atom. And the total amount of the glass substances is 10 to 40 parts by weight.

  When the total amount of cellulose acetate and glass material is less than 10 parts by weight, it tends to be difficult to obtain desired flame retardancy. When the total amount of cellulose acetate and glass material exceeds 40 parts by weight, the effect is saturated. It is not preferable because the processability at the time of fiberization is inferior. Preferably it is 20-30 weight part.

  When the amount of cellulose acetate added is less than 5 parts by weight, a sufficient amount of cellulose acetate carbide necessary for maintaining the form during combustion cannot be obtained. In any case, it tends to be difficult to obtain the desired flame retardancy. Preferably it is 10-20 weight part.

  Furthermore, when the amount of glass material added is less than 5 parts by weight, the glass material necessary for maintaining the form during combustion is insufficient, and when it exceeds 35 parts by weight, the form during combustion can be maintained, but a pseudo mattress test is performed. In any case, it tends to be difficult to obtain desired flame retardancy in any case. Preferably it is 10-20 weight part.

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 halogenated compounds such as hexabromobenzene, hexabromocyclododecane, chlorinated paraffin, halogen-containing phosphorus compounds such as tris (2,3-dichloropropyl) phosphate, ammonium polyphosphate, dibutylaminophosphate, and the like. Phosphorus compounds, magnesium compounds such as magnesium oxide, magnesium hydroxide, magnesium carbonate, oxidized varnish, metastannic acid, oxyhalogenated varnish, stannous hydroxide, tin tetrachloride, ZnSnO ₃ , ZnSn (OH) ₆ , Magnesium stannate, zirconium stannate, zinc stannate, zinc hydroxystannate and other tin compounds, zinc oxide, zinc borate and other zinc compounds, molybdenum oxide and other molybdenum compounds, titanium oxide, barium titanate, etc. Titanium compound, sulfuric acid Nitrogen compounds such as lamin and guanidine sulfamate, aluminum compounds such as aluminum hydroxide, zirconium compounds such as zirconium oxide, antimony compounds such as antimony trioxide, antimony tetraoxide, antimony pentoxide, sodium antimonate, etc. However, it is not limited to these.

  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. 5 to 30 parts by weight of cellulose acetate, 5 to 35 parts by weight of glass material, and 10 to 40 parts by weight in total of the cellulose acetate and the glass material with respect to 100 parts by weight of the polymer containing 17% by weight or more of halogen atoms When the flame retardant synthetic fiber (A) contained so as to be burned by another flame source, cellulose acetate forms a carbide, but the glass material melted at a high temperature during combustion physically binds to this carbide. When solidified, a strong carbonized layer is formed. As a result, the fiber (A) retains its form in the state of carbide without being disintegrated even after combustion, so that the flame is cut off and further fire spread is suppressed. Therefore, it is estimated that highly flame retardancy is exhibited.

  The natural fiber and / or chemical fiber (B) used in the present invention is for imparting excellent texture, touch, design, product strength, washing resistance and durability to the flame retardant fabric of the present invention. It is a component that improves processability when using a flame-retardant nonwoven fabric for bedding and furniture.

  Specific examples of the natural fibers include plant fibers such as cotton and hemp, animal fibers such as wool, camel hair, goat wool, and silk, and specific examples of chemical fibers include viscose rayon fibers. , Recycled fiber such as cupra fiber and acetate fiber, special recycled fiber containing water glass component in viscose rayon (Visil registered trademark made by Cetello Saquestio), nylon fiber, polyester fiber, polyester low melting point binder fiber, acrylic fiber Synthetic fibers such as, but not limited to. 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 in combination with the flame retardant synthetic fiber (A).

  In the present invention, a polyester-based fiber generates a melt upon combustion, and the carbonized layer formed by the flame-retardant nonwoven fabric becomes stronger by covering the flame-retardant nonwoven fabric, so that the bedding even if exposed to intense flames for a long time It can provide flame shielding barrier performance to prevent flames from being applied to cotton and urethane foam used for furniture and furniture, it is easy to obtain bulkiness when processed into non-woven fabric, and the fiber (A) in the opening machine (card) In order to alleviate the damage of the fiber due to the problem of strength, the fiber (B) is preferably blended at a ratio of 40% by weight or less with respect to the flame retardant fiber composite, more preferably 15 to 25% by weight. preferable.

  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. Further, when a polyester fiber having a low melting point is used, a simple needle punch method can be adopted when forming a nonwoven fabric.

  In the present invention, the flame-retardant fiber composite 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). The mixing ratio includes the flame retardancy required for the final product manufactured from the resulting flame-retardant nonwoven fabric, as well as water absorption, texture, moisture absorption, touch, design, product strength, wash resistance, durability, etc. Determined according to quality. 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 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. It is insufficient and it is difficult to obtain a desired high flame retardancy. On the other hand, when the amount of the flame retardant synthetic fiber (A) exceeds 90% by weight, that is, when the fiber (B) is less than 10% by weight, the hot melt adhesiveness is insufficient and the strength of the obtained nonwoven fabric is lowered. However, the workability tends to be reduced.

  When the hot melt bonding method is selected at the time of producing the fiber composite, it is preferable that at least 10% by weight of the polyester-based low melting point binder fiber is contained as the natural fiber and / or the chemical fiber (B).

  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 is made of the above-mentioned flame retardant fiber composite, and examples thereof include bedding such as a bed mattress, a chair, a sofa, and a vehicle seat.

  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 with excellent texture and touch can be obtained.

  On the other hand, as chairs used indoors, tools, benches, side chairs, armchairs, lounge chairs, 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 using low-resilience urethane foam having a pressure dispersion function, such as Tempur World (Tempur World, Inc., registered trademark), a foam made by foaming ordinary styrene or urethane resin 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. Further, 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 from above.

  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.

  Hereinafter, the present invention will be described in more detail with reference to examples. However, the present invention is not limited to the examples.

<Flame resistance evaluation by LOI value>
The flame retardancy of the halogen-containing fibers in the examples was evaluated by measurement using LOI values. Take 2g of the fiber produced according to the following production example, divide it 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 to keep burning for 5 cm was measured, and this was taken 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.

<Flame retardant evaluation by nonwoven fabric composite>
The flame retardancy of the flame retardant fiber composites in the examples was measured as follows using a nonwoven fabric. This is because the flame-retardant nonwoven fabric of the present invention is sandwiched between a surface fabric such as upholstered furniture such as a mattress, chair, sofa, etc. and urethane foam or cotton pad that is an internal structure, so that the bedding in the event of a fire It is a simple evaluation method that is supposed to prevent the ignition of the internal structure of furniture and furniture.

1) Preparation of nonwoven fabric composite After the fibers mixed at a predetermined ratio were opened with a card, a nonwoven fabric with a basis weight of 400 g / m ² and a basis weight of 20 cm × width 20 cm was prepared by a needle punch method. The lower surface of the nonwoven fabric was wrapped with a polyester woven fabric (weight per unit area: 120 g / cm ² ) as a surface fabric to obtain a nonwoven fabric composite for flame retardancy evaluation test.

2) Flame retardant test using non-woven fabric composite Prepare a non-woven composite with a perforated plate of 200mm length × width 200mm × thickness 10mm with a hole with a diameter of 15cm in the center, and a surface fabric on the bottom. The sample was set and fixed with clips so that the nonwoven fabric composite did not shrink during heating. The sample was set on a gas stove (PA-10H-2) manufactured by Paloma Industry Co., Ltd. so that the center of the sample and the center of the burner were aligned at a position 40 mm from the burner surface. The fuel gas used was propane with a purity of 99% or more, the flame height was 25 mm, and the flame time was 180 seconds. The evaluation criteria are as follows. ◎ or ○ was accepted.
◎: No non-uniformity in thickness and holes in non-woven fabric composite after test ○: There is thickness unevenness but no holes ×: Thickness unevenness and holes are open

<Evaluation of flame retardancy with simulated mattress>
The flame retardancy of the flame retardant fiber composites in the examples was evaluated using a pseudo mattress as follows. This is a simple evaluation method that imitates the flame retardant evaluation method for bed mattresses in the United States and the US federal method 16CFRpart1632.

1) Production of pseudo mattress After the fibers mixed at a predetermined ratio were opened with a card, a non-woven fabric having a basis weight of 400 g / m ² and a basis weight of 30 cm × width 30 cm was produced by a thermal fusion method. As shown in FIGS. 1 and 2, the non-woven fabric (3) is placed on a polyurethane foam (1), (2) (density 18 kg / m ³ ) having a length of 30 cm × width of 30 cm × thickness of 5 cm, and a surface fabric (4 ) After wrapping the nonwoven fabric (3) and polyurethane foam (1), (2) with a polyester woven fabric (weight per unit of 120 g / cm ² ), the front diagonal line is quilted with an industrial quilt sewing machine (manufactured by Juki Co., Ltd.). A pseudo mattress was used.

2) Flame Retardancy Test with Pseudo Mattress Four ignited cigarettes were placed on the quilt portion of the pseudo mattress, and the test was started. The combustion condition of the pseudo mattress after completion of the test was evaluated as follows in accordance with US Federal Law 16CFRpart1632. ○ or △ was accepted, and even one with x was rejected.
○: In each tobacco, 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. Surface carbonization range exceeds 2 inches from tobacco

<Comprehensive judgment>
Those that passed both the evaluation by the nonwoven fabric composite and the evaluation by the pseudo mattress were evaluated as ◯, and at least one of the evaluations was determined as ×. ○ is a pass.

Production Example 1
100 parts of a copolymer consisting of 51% by weight of acrylonitrile, 48% by weight of vinylidene chloride and 1% by weight of sodium p-styrenesulfonate (halogen atom ratio: 35% by weight) is added to acetone so that the resin concentration becomes 30% by weight. Cellulose acetate (acetylation degree 55%, polymerization degree 170) and glass materials (glass transition temperature 240 ° C., P ₂ O ₅ —ZnO) in the amounts shown in Table 1 with respect to the resin weight of the resin solution obtained after dissolution. System, ZP450) manufactured by Asahi Fiber Glass Co., Ltd. was added to obtain a spinning dope. This spinning dope was extruded into a 30% by weight 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 140 ° C., stretched 2.5 times, and then further 150 A halogen-containing fiber was obtained by heat treatment at 5 ° C. for 5 minutes and further cutting. The obtained fiber was a fine fiber having a fineness of 7.8 dtex and a cut length of 64 mm.

Production Example 2
100 parts of a copolymer consisting of 49% by weight of acrylonitrile, 50% by weight of vinyl chloride and 1% by weight of sodium p-styrenesulfonate (halogen atom ratio: 29% by weight) is added to acetone so that the resin concentration becomes 30% by weight. Cellulose acetate (acetylation degree 55%, polymerization degree 170) and glass materials (glass transition temperature 240 ° C., P ₂ O ₅ —ZnO) in the amounts shown in Table 1 with respect to the resin weight of the resin solution obtained after dissolution. System, ZP450) manufactured by Asahi Fiber Glass Co., Ltd. was added to obtain a spinning dope. This spinning dope was extruded into a 30% by weight 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 130 ° C., then stretched 2.5 times, and then further 140 A halogen-containing fiber was obtained by heat treatment at 5 ° C. for 5 minutes and further cutting. The obtained fiber was a fine fiber having a fineness of 7.8 dtex and a cut length of 64 mm.

Examples 1-5 and Comparative Examples 1-3
According to Production Example 1, a nonwoven fabric prepared by mixing cellulose acetate, a glass fiber containing halogen-containing fiber, rayon fiber, and polyester fiber in a weight ratio of 40:40:20 is prepared, and flame retardancy is achieved. evaluated. The results are shown in Table 1.

  In Examples 1 to 5, the LOI value was high, and both evaluation methods of the nonwoven fabric composite and the pseudo mattress were good, and passed in the comprehensive judgment. In Comparative Example 1, since both the glass component and the cellulose acetate component were insufficient, the LOI value was low, and the evaluation with the nonwoven fabric composite failed. In Comparative Examples 2 and 3, since either the glass component or the cellulose acetate component is insufficient, in Comparative Example 2, the LOI value is low, the flame retardancy is inferior, and the flame retardancy test with the nonwoven fabric composite is rejected. It was. In Comparative Example 3, the LOI value was high and the flame retardant test with the nonwoven fabric composite was passed, but the flame retardant test with a pseudo mattress was rejected, and the comprehensive judgment was rejected.

Examples 6-7 and Comparative Examples 4-5
Using the halogen-containing fibers of Example 2, non-woven fabrics having rayon fibers and polyester fibers in the mixing ratios shown in Table 2 were prepared, and flame retardancy was evaluated. The results are shown in Table 2.

  In Examples 6 to 7, both the nonwoven fabric composite and the simple mattress were good in the evaluation method, and passed in the comprehensive judgment. In Comparative Example 4, the amount of halogen-containing fibers was insufficient, and in Comparative Example 5, the amount of halogen-containing fibers was excessive, so the overall judgment was rejected.

Examples 8 to 10 and Comparative Examples 6 to 8
In accordance with Production Example 2, a non-woven fabric was prepared by mixing cellulose acetate, a glass-containing halogen-containing fiber, rayon fiber, and polyester fiber in a weight ratio of 40:40:20, respectively. evaluated. The results are shown in Table 3.

  In Examples 8 to 10, the LOI value was high, and both the nonwoven fabric composite and the pseudo mattress were evaluated well, and passed in the comprehensive judgment. In Comparative Example 6, since both the glass component and the cellulose acetate component were insufficient, the LOI value was low, and the evaluation with the nonwoven fabric composite failed. In Comparative Examples 7 and 8, since either the glass component or the cellulose acetate component is insufficient, Comparative Example 7 has a low LOI value and inferior flame retardancy, and fails the flame retardancy test with the nonwoven fabric composite. It was. Although the comparative example 8 had high LOI value and passed the flame-retardant test by a nonwoven fabric composite, it failed the flame-retardant test by the pseudo mattress, and failed by comprehensive judgment.

It is a structure (overall view) of a pseudo mattress for flame retardancy evaluation. It is AA sectional drawing of the pseudo mattress for flame-retardant evaluation of FIG.

Explanation of symbols

1, 2 Polyurethane foam 3 Non-woven fabric 4 Surface fabric 5 Quilt part 6 Base material

Claims (11)

5 to 30 parts by weight of cellulose acetate, 5 to 35 parts by weight of glass material, and 10 to 40 parts by weight in total of the cellulose acetate and the glass material with respect to 100 parts by weight of the polymer containing 17% by weight or more of halogen atoms Flame retardant synthetic fiber to be included. The polymer containing 17% by weight or more of the halogen atom contains 30 to 70% by weight of acrylonitrile units, 70 to 30% by weight of halogen-containing vinyl monomer units and / or halogen-containing vinylidene monomer units, and The flame-retardant synthetic fiber according to claim 1, comprising 0 to 10% by weight of a polymerizable vinyl monomer unit. The flame retardant synthetic fiber according to claim 1 or 2, wherein the cellulose acetate is diacetyl cellulose and / or triacetyl cellulose. The flame-retardant synthetic fiber according to any one of claims 1 to 3, wherein the glass substance has a glass transition temperature of 200 to 700 ° C. The glass material is SiO ₂ —PbO, SiO ₂ —PbO—ZnO, SiO ₂ —B ₂ O ₃ —Na ₂ O, SiO ₂ —B ₂ O ₃ —PbO, SiO ₂ —Al ₂ O _3. , B ₂ O ₃ —PbO, B ₂ O ₃ —ZnO, B ₂ O ₃ —Na ₂ O—PbO, B ₂ O ₃ —PbO—ZnO, B ₂ O ₃ —P ₂ O _{5 , B 2 O 3 -Bi 2 O} 3 -ZnO system and at least one flame retardant synthetic fibers according to claim 4, wherein is selected from P ₂ O ₅ -ZnO system. (A) A flame retardant fiber composite comprising 10% by weight or more of the flame retardant synthetic fiber according to any one of claims 1 to 5 and (B) 90% by weight or less of at least one kind of natural fiber and chemical fiber body. 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 any one of claims 6 to 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. The upholstered furniture product using the flame-retardant fiber composite according to any one of claims 6 to 10.

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