JP2008019540A - Flame-retardant fiber product using plush fabric - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a flame-retardant fiber product comprising a plush fabric as a surface cloth, having a reduced burning rate when exposed to a flame while maintaining a good appearance and texture required for an object for interiors, without applying a flame-retardant processing such as mixing or coating, etc., of the flame retarder to the ground yarn, back coating agent constituting the base of the plush fabric. <P>SOLUTION: The flame-retardant fiber product is composed of 30-100 wt.% of acrylic fibers fibers composing a pile part, the plush fabric composed of ground yarn and back coating with non flame retardant properties as the surface cloth, and non flame retardant filler is filled inside, wherein the polymers constituting the acrylic fibers comprises 30-70 wt.% of acrylonitrile, 30-65 wt.% of at least one selected from vinyl based monomer comprising a halogen atom and a vinylidene monomer containing halogen. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention relates to a flame-retardant fiber product suitable for interior use such as a cushion and a pillow. More specifically, the present invention relates to a flame retardant fiber product using a raised fabric as a surface fabric.

  There is a strong demand from the market for the flame retardant of interior-use textile products with an internal filling material covered with a fabric. For example, in recent years, the United States has been enacted with a law on the method of flame testing of textile products. Yes. Examples of the textile products include daily commodities such as cushions, pillows, bed cushions, and futons. Generally, as a filling material filled in the cushions and pillows, synthetic fibers of polyester and polypropylene, urethane foams are used. Resin molded products such as, natural fibers such as feathers and cotton are used. In addition, as a fabric covering the filling material, a napped fabric may be used in order to give an appearance and texture like natural fur.

  As a method for suppressing the burning rate when exposed to a flame to a certain rate or less for a fiber product such as a cushion or pillow covered with a non-flammable filling material as described above, a napped fabric is used. There has been proposed a method of applying a processing such as mixing or applying a flame retardant to a back coating agent to be applied for fixing a ground yarn or a pile portion constituting the base fabric. However, such a method has a problem that the process is complicated by performing the flame retardant processing and the cost is increased by adding a flame retardant.

  Therefore, in view of the above-mentioned situation, the present invention intends to solve without subjecting the ground yarn or the back coating agent constituting the surface fabric of the raised fabric to be processed or mixed with a flame retardant. An object of the present invention is to obtain a flame-retardant fiber product that can suppress the burning rate when exposed to flame while maintaining the good appearance and texture required for interior use.

  The present invention relates to a textile product suitable for interior use using a raised fabric as a surface fabric, and is required for interior use by containing specific fibers in a specific ratio as fibers constituting the pile portion of the raised fabric. The present inventors have found out that it is possible to suppress the burning rate of a textile product to a certain value or less even when a combustible material is used as an internal filling material while maintaining a good appearance and texture.

  That is, in the flame retardant fiber product according to the present invention, the fiber constituting the pile portion contains 30 to 100% by weight of acrylic fiber, and the ground yarn and the back coating agent constituting the base fabric are flame retardant. A napped fabric made of a non-flammable material is used as a surface fabric, and a filling material that is not flame retardant is filled inside, and the polymer constituting the acrylic fiber is 30 to 70% by weight of acrylonitrile, a halogen-containing vinyl It contains 30 to 65% by weight of at least one of a monomer and a halogen-containing vinylidene monomer.

  Here, the raised fabric refers to a fabric having a loop-like pile portion or a tuft-like pile portion (one obtained by cutting a loop) on the surface of the base fabric, and is particularly limited to those obtained by weaving. For example, it is a concept including what is obtained by knitting. Moreover, a back coating agent means the adhesive agent apply | coated to the back surface of a base fabric in order to fix a pile part.

  In addition, each measurement interval measured every minute from immediately after the end of flame contact to 6 minutes after a flame having a flame length of 35 mm from the lower surface of the end of the fiber product left in a horizontal position with a butane gas burner for 20 seconds. It is preferable that the rate of decrease in the weight of the fiber product is all 20 g / min.

The weight per unit area of the raised fabric is 450~1100g / m ^2, and the ground yarns constituting the base fabric, upstanding bristles fabric per unit area weight is 30~180g / m ^2, and The back coating agent preferably has a weight per unit area of the raised fabric of 20 to 80 g / m ² .

  Furthermore, it is preferable that the pile length of the raised fabric is 7 to 100 mm.

  Moreover, it is preferable that the ground yarn which comprises the said base fabric consists of polyester.

  Moreover, it is preferable that the said back coating agent consists of acrylic ester.

  Furthermore, the filling material is preferably at least one selected from the group consisting of polyester fiber, polyester resin, polypropylene fiber, polypropylene resin, urethane foam, feathers and cotton.

  The flame-retardant fiber product according to the present invention as described above is capable of suppressing the burning rate when exposed to flame while maintaining a good appearance and texture required for interior use, and is a napped material that is a surface fabric. Since it is not necessary to perform processing such as mixing and application of flame retardant to the ground yarn and back coating agent constituting the fabric base fabric, the productivity is good and the cost is low.

  As described above, in the flame-retardant fiber product according to the present invention, the fiber constituting the pile portion contains 30 to 100% by weight of acrylic fiber, and the ground yarn and the back coating agent constituting the base fabric are difficult. A napped fabric made of a non-flammable material is used as a surface fabric, and a filling material that is not flame retardant is filled inside, and the polymer constituting the acrylic fiber contains 30 to 70% by weight of acrylonitrile, halogen It is characterized by containing 2 to 65% by weight of at least one of a vinyl-containing monomer and a halogen-containing vinylidene monomer.

  The filling material to be filled in the flame-retardant fiber product according to the present invention is not particularly limited as long as it is not flame-retardant. For example, polyester or polypropylene synthetic fiber, polyester or polypropylene synthetic resin Resin molded products such as urethane foam, natural fibers such as feathers or cotton, and the like are preferably used because they have a texture such as good softness. The filling material may be appropriately selected and used according to various properties such as bulkiness required for the final fiber product, shape, comfort and handling.

  Further, the raised fabric used as the surface fabric of the flame-retardant fiber product according to the present invention is such that the fiber constituting the pile portion contains 30 to 100% by weight of the acrylic fiber, and the acrylic fiber is 50 to 50%. More preferably 100% by weight is contained. By setting the ratio of the acrylic fiber within the range of 30 to 100% by weight, the burning speed when exposed to flame is imparted to the raised fabric with the animal hair-like texture of the acrylic fiber. It can be suppressed small. On the other hand, if the content of the acrylic fiber is less than 30% by weight, a napped fabric having sufficient flame retardancy cannot be obtained.

  In the acrylic fiber, the polymer constituting the fiber is 30 to 70% by weight of acrylonitrile and at least one of a halogen-containing vinyl monomer and a halogen-containing vinylidene monomer (hereinafter simply referred to as “halogen-containing monomer”). The amount of the acrylonitrile is preferably 40 to 60% by weight. Preferably, the content ratio of the halogen-containing monomer is 40 to 55% by weight. By making the content ratio of the acrylonitrile 30 to 70% by weight and the content ratio of the halogen-containing monomer 30 to 65% by weight, it is possible to impart animal hair-like texture to the raised fabric that is the surface fabric, The required flame retardancy can be imparted to the final textile product. When the content ratio of the halogen-containing monomer is less than 30% by weight, it is difficult to make the napped fabric flame-retardant. Further, the acrylic fiber has 30 to 70% by weight of acrylonitrile and 30 to 65% by weight of a halogen-containing monomer (that is, at least one of a halogen-containing vinyl monomer and a halogen-containing vinylidene monomer). In addition to%, it is preferable to contain other vinyl monomers copolymerizable therewith.

Examples of the halogen-containing vinyl monomer include vinyl chloride, vinyl bromide, vinyl fluoride and the like, and examples of the halogen-containing vinylidene monomer include:
Examples include vinylidene chloride, vinylidene bromide, and vinylidene fluoride.

  Examples of other vinyl monomers copolymerizable with the acrylonitrile and the halogen-containing monomer include, for example, acrylic acid esters such as methyl acrylate and methyl methacrylate, methacrylic acid esters, and glycidyl methacrylate. Esters of unsaturated carboxylic acids, vinyl esters typified by vinyl acetate and vinyl acetate, vinyl amides typified by acrylamide and methacrylamide, methacryl sulfonic acid and other vinyl pyridine, methyl vinyl ether, methacrylonitrile, etc. A well-known vinyl compound is mentioned, These may use 2 or more types together.

  Furthermore, when at least one of the acrylonitrile and other vinyl monomers copolymerizable with the halogen-containing monomer is a sulfonic acid group-containing vinyl monomer, the dyeability is improved, which is more preferable. . Examples of the sulfonic acid group-containing vinyl monomer include styrene sulfonic acid, parastyrene sulfonic acid, acrylic sulfonic acid, methacryl sulfonic acid, parameter acryloyloxybenzene sulfonic acid, methacryloyloxypropyl sulfonic acid, or metal salts and amines thereof. Examples include salts.

  As other fibers used in combination with 30 to 100% by weight of the acrylic fibers as the fibers constituting the pile portion of the napped fabric, non-flammable fibers can be used, for example, acrylic fibers or polyester-based fibers. Examples thereof include, but are not limited to, fibers, polyamide fibers, polyolefin fibers, and polyurethane fibers. Here, the acrylic fiber refers to a fiber containing acrylonitrile in excess of 70% by weight. In addition, as a fiber which comprises the pile part of the said raised fabric, it is a matter of course that the fiber which consists of 100% of the said acrylic fiber may be used without including these non-flammable fibers at all.

  In addition, the pile length of the raised fabric is set in a range of 7 mm to 100 mm in order to set the pile length according to the texture required for the final product in order to reproduce various natural fur tones such as beaver, mink, fox, etc. What is necessary is just to set suitably. In addition, the fineness, fiber cross-sectional shape, hue, fiber shrinkage ratio, etc. of the fibers constituting the pile portion of the raised fabric may be set as appropriate according to the texture required for the final product.

  As the ground yarn constituting the base fabric of the raised fabric in the present invention, non-flame retardant yarns can be used. For example, acrylic fiber spun yarn or polyester filament is suitable.

  In addition, as the back coating agent applied to the back surface of the base fabric to fix the pile portion, it has the adhesive strength required as a back coating agent for napped fabrics, has no alteration of the adherend surface, and is handled. Those that do not easily cause problems in the working environment are preferred, but acrylic ester resins typified by ester polymers of acrylic acid and methacrylic acid are particularly preferred because of the flexibility of the film, transparency, and ease of handling. Further, the acrylic ester resin is more preferably used as an emulsion.

Preferably, the weight of the raised fabric per unit area is 450 to 1100 g / m ^2, and the weight of the ground yarn constituting the base fabric is 30 to 180 g / m per unit area of the raised fabric. ² and the weight per unit area of the raised fabric of the back coating agent is 20 to 80 g / m ² , the weight ratio of the pile portion, the base fabric and the back coating agent in the raised fabric becomes balanced. In addition, it has flame retardant properties while having a good texture required as a surface fabric for textiles. More preferably, the weight per unit area of the raised fabric is 500 to 800 g / m ^2, and the weight of the ground yarn constituting the base fabric is 50 to 100 g / m ² per unit area. When the weight of the back coating agent per unit area of the raised fabric is 30 to 60 g / m ² , a raised fabric with a better balance is obtained.

  As the flame retardancy imparted to the final textile product, the flame disappears immediately after completion of the flame contact when a flame having a flame length of 35 mm is indirectly flamed with a butane gas burner from the lower surface of the end of the textile product left horizontally. It can be used as a preferable index that the rate of decrease in the weight of the fiber product in each measurement section measured every minute until 20 g / min or less, and the fiber product according to the present invention is configured as described above. By adopting, it has the required flame retardance while maintaining the good appearance and texture required for interior use.

  Hereinafter, the present invention will be described by way of examples.

(Example 1)
Commercially available acrylic fiber “Kanekalon (registered trademark) RCL (R / W), halogen-containing monomer content 50% by weight, fineness 7.8 dtex, 38 mm, manufactured by Kaneka Corporation” and commercially available non-flammable acrylic The fibers “Exlan (registered trademark) K691, fineness 3.3 dtex, 32 mm, manufactured by Nippon Exlan Industry Co., Ltd.” were respectively (1) 100% / 0%, (2) 70% / 30%, and (3) 50%. / 50%, (4) 30% / 70% by weight ratio, softener and antistatic agent are added, and after opening and blending with an opener, sliver (1) to ( 4) was created. Each of these slivers (1) to (4) was knitted on a raised fabric (long pile, high pile) knitting machine together with polyester filament 165 dtex (50 filaments) constituting the base fabric structure. The sliver input weight at this time was 550 g / m ² per unit volume of the finished raised fabric, and the polyester filament input weight was 100 g / m ² per unit volume of the finished raised fabric. Next, preliminary polishing and preliminary shearing were performed at 120 ° C. to trim the pile length, and then an acrylic ester resin was adhered to the back of the napped fabric, followed by drying and fixing with a tenter. The adhesion amount of the acrylic ester resin after drying was 35 g / m ² per unit volume of the finished napped fabric. Further, polishing and shearing were performed in the order of 150 ° C., 130 ° C., 120 ° C., and 100 ° C. to prepare napped fabrics (1) to (4) having a pile length of 15 mm.

  Each of the finished raised fabrics (1) to (4) is sewn into a bag shape with a sewing machine to a size of warp 380 mm × weft 380 mm, and then filled with 250 g of polyester fiber 6.8 dtex, 38 mm as a filling material. Cushions (1) to (4) as final fiber products corresponding to the slivers (1) to (4) were created by sewing the mouth with a sewing machine.

  Each of these cushions (1) to (4) is placed horizontally on a digital weighing scale, and a flame with a flame length of 35 mm is indirectly fired with a butane gas burner for 20 seconds from the lower surface of the end, and the product weight after removing the flame is measured. Weighed every 20 seconds. As a result, the cushions (1) to (3) self-extinguish before spreading to the internal filling material, and the cushion weight in each measurement section measured every minute from 6 minutes after the end of flame contact. The decrease rate was 0 to 3 g / min for the cushion (1), 0 to 7.5 g / min for the cushion (2), and 4.5 to 19 g / min for the cushion (3). On the other hand, in the cushion (4), although the inner filling material was flared, the rate of decrease in the cushion weight in each measurement section measured every minute from immediately after flame contact to 6 minutes later was 9.3- It became 18 g / min, and the combustion rate could be suppressed small.

(Example 2)
Commercially available acrylic fiber “Kanekalon (registered trademark) LAN (R / W), halogen-containing monomer content 50% by weight, fineness 7.8 dtex, 127 mm” and commercially available acrylic fiber “Kanekalon (registered trademark) RCL , Halogen-containing monomer content 50% by weight, fineness 3.3 dtex, 127 mm, manufactured by Kaneka Corporation, and commercially available non-flame retardant acrylic fiber “Exlan (registered trademark) K67, fineness 3.3 dtex, 64 mm, Japan Exlan Kogyo Co., Ltd. ”(1) 10% / 50% / 40% and (2) 10% / 40% / 50% weight ratio, respectively, and softener and antistatic agent are added. After performing defibration and blending with an opener, sliver (1) and (2) were created with a card. Each of these slivers (1) and (2) was aligned with a gil, and a roving was obtained. This was spun by a ring spinning machine to obtain 1 / 14th worsted yarn. This worsted yarn was knitted with a knitting machine together with polyester filament 165 dtex (50 filaments) constituting the base fabric structure. At this time, the input weight of the worsted yarn was 500 g / m ² per unit volume of the finished raised fabric, and the input weight of the polyester filament was 100 g / m ² per unit volume of the finished raised fabric. Next, after removing the pile length by twisting and deflaming the worsted yarn by brushing, pre-polishing at 120 ° C and pre-shearing, the acrylic ester resin was attached to the back of the napped fabric, and dried and fixed with a tenter Went. The adhesion amount of the acrylic ester resin after drying was 30 g / m ² per unit volume of the finished napped fabric. Further, polishing and shearing were performed in the order of 150 ° C., 130 ° C., 120 ° C., and 100 ° C. to produce napped fabrics (1) and (2) having a pile length of 15 mm.

  The finished raised fabrics (1) and (2) are sewed into a bag shape by a sewing machine to a size of warp 380 mm x weft 380 mm, and then filled with 250 g of polyester fiber 6.8 dtex, 38 mm as a filling material. Were sewed with a sewing machine, and cushions (1) and (2) as final fiber products corresponding to the sliver (1) and (2), respectively, were prepared.

  These cushions (1) and (2) are placed horizontally on a digital weighing scale, and a flame with a flame length of 35 mm is indirectly flamed by a butane gas burner for 20 seconds from the bottom of the end, and the product weight after removing the flame is 20 Weighed every second. As a result, in the cushions (1) and (2), the self-extinguishing before spreading to the internal filling material, and the cushion weight in each measurement section measured every minute from 6 minutes after the end of flame contact. The decrease rate was 10 to 20 g / min for the cushions (1) and (2), and the combustion rate could be reduced.

(Comparative Example 1)
Commercially available acrylic fiber “Kanekalon (registered trademark) RCL (R / W), halogen-containing monomer content 50% by weight, fineness 7.8 dtex, 38 mm, manufactured by Kaneka Corporation” and commercially available non-flammable acrylic The fibers “Exlan (registered trademark) K691, fineness 3.3 dtex, 32 mm, manufactured by Nippon Exlan Industry Co., Ltd.” were respectively (1) 20% / 80%, (2) 10% / 90%, and (3) 0%. The sliver (1) to (3) was prepared with a card after being used at a weight ratio of / 100%, further provided with a softening agent and an antistatic agent, defibrated and blended with an opener. Each of these slivers (1) to (3) was knitted on a napped fabric (long pile, high pile) knitting machine together with polyester filament 165 dtex (50 filaments) constituting the base fabric structure. The sliver input weight at this time was 550 g / m ² per unit volume of the finished raised fabric, and the polyester filament input weight was 100 g / m ² per unit volume of the finished raised fabric. Next, preliminary polishing and preliminary shearing were performed at 120 ° C. to trim the pile length, and then an acrylic ester resin was adhered to the back of the napped fabric, followed by drying and fixing with a tenter. The adhesion amount of the acrylic ester resin after drying was 35 g / m ² per unit volume of the finished napped fabric. Further, polishing and shearing were performed in the order of 150 ° C., 130 ° C., 120 ° C., and 100 ° C. to prepare napped fabrics (1) to (3) having a pile length of 15 mm.

  The finished raised fabrics (1) to (3) are sewed into a bag shape with a sewing machine to a size of 380 mm x 380 mm, and then filled with 250 g of polyester fiber 6.8 dtex and 38 mm as a filling material. Cushions (1) to (3) as final fiber products corresponding to the slivers (1) to (3) were prepared by sewing with a sewing machine.

  Each of these cushions (1) to (3) is placed horizontally on a digital weighing scale, and a flame with a flame length of 35 mm is indirectly flamed with a butane gas burner for 20 seconds from the bottom of the end, and the product weight after removing the flame is measured. Weighed every 20 seconds. As a result, in the cushions (1) to (3), the rate of decrease in the cushion weight in each measurement section measured every minute from the time immediately after the flame contact to 6 minutes after flaming the internal filling material, The cushion (1) was 30.2 to 56.7 g / min, the cushion (2) was 63 to 111 g / min, and the cushion (3) was 123.3 to 136.8 g / min. In particular, in the cushion (3), even the polyester filled therein was completely burned.

(Comparative Example 2)
Commercially available non-flame retardant acrylic fiber “Exlan K191 (R / W), fineness 19 dtex, 127 mm, manufactured by Japan Exlan Industrial Co., Ltd.” and commercially available non-flame retardant acrylic fiber “Exlan (registered trademark) K191, fineness 5. 6 dtex, 127 mm, manufactured by Nippon Exlan Industry Co., Ltd. ”and commercially available non-flame retardant acrylic fiber“ Exlan (registered trademark) K67, fineness 3.3 dtex, 64 mm, manufactured by Nippon Exlan Industry Co., Ltd. ”(1) 10 % / 50% / 40% in weight ratio, softener and antistatic agent were further applied, and after opening and blending with an opener, a sliver (1) was made with a card. After this sliver (1) was aligned with a gil, a roving was obtained. This was spun by a ring spinning machine to obtain 1 / 16th worsted yarn. This worsted yarn was knitted with a knitting machine together with polyester filament 165 dtex (50 filaments) constituting the base fabric structure. At this time, the input weight of the worsted yarn was 500 g / m ² per unit volume of the finished raised fabric, and the input weight of the polyester filament was 100 g / m ² per unit volume of the finished raised fabric. Next, after removing the pile length by twisting and deflaming the worsted yarn by brushing, pre-polishing at 120 ° C and pre-shearing, the acrylic ester resin was attached to the back of the napped fabric, and dried and fixed with a tenter Went. The adhesion amount of the acrylic ester resin after drying was 30 g / m ² per unit volume of the finished napped fabric. Further, polishing and shearing were performed in the order of 150 ° C., 130 ° C., 120 ° C., and 100 ° C. to prepare a raised fabric (1) having a pile length of 15 mm.

  The finished raised fabric (1) is sewn into a bag shape with a sewing machine to a size of warp 380 mm × weft 380 mm, filled with 250 g of polyester fiber 6.8 dtex, 38 mm as a filling material, and then the filling port is stitched with a sewing machine. Thus, a cushion (1) as a final fiber product was prepared.

This cushion (1) is placed horizontally on a digital weighing scale, and a flame with a flame length of 35 mm is indirectly flamed with a butane gas burner for 20 seconds from below the end, and the product weight after removing the flame is measured every 20 seconds. did. As a result, in the cushion (1), the internal filling material was flared, and the cushion weight reduction rate in each measurement section measured every minute from immediately after the flame contact to 6 minutes was 30 g to 35 g / Minutes and the burning rate increased.

Claims (7)

While using the napped fabric which the fiber which comprises a pile part contains 30-100 weight% of acrylic fibers, and the ground yarn and back coating agent which comprise a base fabric consist of a material which is not a flame-retardant, as a surface fabric, Filled with a non-flammable filling material,
The polymer constituting the acrylic fiber contains 30 to 70% by weight of acrylonitrile and 30 to 65% by weight of at least one of a halogen-containing vinyl monomer and a halogen-containing vinylidene monomer. ,
A flame-retardant fiber product characterized by that.   When a flame having a flame length of 35 mm is indirectly flamed with a butane gas burner for 20 seconds from the lower surface of the end of the textile product left in the horizontal direction, the measurement period in each measurement section measured every minute from immediately after flame contact to 6 minutes later 2. The textile product according to claim 1, wherein the decrease rate of the textile product weight is 20 g / min or less. The weight per unit area of the raised fabric is 450~1100g / m ^2, and the base fabric of ground yarn constituting the weight per area upstanding bristles fabric unit 30~180g / m ^2, and the back coatings, textile products according to claim 1 or 2 wherein the weight per upstanding bristles fabric unit area is 20 to 80 g / m ^2.   The textile product according to any one of claims 1 to 3, wherein the pile length of the raised fabric is 7 to 100 mm.   The textile product according to any one of claims 1 to 4, wherein the ground yarn constituting the base fabric is made of polyester.   The textile product according to any one of claims 1 to 5, wherein the back coating agent comprises an acrylic ester. The textile product according to any one of claims 1 to 6, wherein the filling material is at least one selected from the group consisting of polyester fiber, polyester resin, polypropylene fiber, polypropylene resin, urethane foam, feathers, and cotton.