JP2008190048A - Flame-retardant nonwoven fabric and upholstered furniture product using the same - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a flame-retardant nonwoven fabric which has high flame retardancy and good processability, retains the intact excellent texture, touch feeling, etc. inherent in the fibrous materials, and has a high designability and comfortableness, and to provide an upholstered furniture product, such as a mattress, which is produced by covering an inner structure with this flame-retardant nonwoven fabric, has been highly flame-proofed, and has a highly designability and comfortableness. <P>SOLUTION: A flame-retardant nonwoven fabric which consists of at least 15 pts.wt. of halogenated fibers (A) having a dry heat shrinkage at 160°C of 5% or lower and containing a glass ingredient, 0-85 pts.wt. of cellulosic fibers (B), and 0-40 pts.wt. of polyester fibers (C), in the total of 100 pts.wt., and has a basis weight of 200 g/m<SP>2</SP>or larger. The upholstered furniture product using the flame-retardant nonwoven fabric has a high self-extinguishing ability, the ability to form a carbonized film, and shape retentivity. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention relates to a flame retardant nonwoven fabric and upholstered furniture products such as a flame retardant mattress using the same.

  In recent years, demands for ensuring safety in clothing, food and housing are increasing. Among these, in order to prevent a fire during sleeping, which is particularly harmful to humans when it occurs, it is an important issue to impart flame retardancy to products such as bedding and furniture.

  In upholstered furniture products, flammable materials such as cotton, polyester, and urethane foam are often used as internal structures and fabrics covering them for comfort and design in use. In order to ensure flameproofing in such upholstered furniture products, the internal structure made of a flammable material is covered with a cloth made of an appropriate flame retardant material, thereby prolonging the flame buildup on the internal structure. It is important to prevent over time. The flame retardant material must have a high level of flame retardancy and does 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 as flame retardant materials used for fabrics covering internal structures. However, there has not yet appeared a combination of high flame retardancy and comfort and design required for upholstered furniture products.

  As a method for imparting flame retardancy to the fabric covering the internal structure, for example, there is a so-called post-processing flameproofing method in which a flameproofing agent is applied to a cotton cloth, but this is due to the difficulty of uniform adhesion of the flameproofing agent. There are problems such as variations in flameproof performance, deterioration in flameproofing performance due to falling off of the flameproofing agent due to washing, etc., and reduction in touch and comfort of the side due to hardening of the fabric due to adhesion of the flameproofing agent. It was.

  In addition, when inexpensive polyester is used as the main material of the fabric covering the internal structure, polyester cannot be a carbonizing component, so when forcedly burned, it melts and has holes to maintain the structure. However, the flame and flame resistance of the cotton and urethane foam used for the above-mentioned bedding and furniture were completely insufficient.

  In addition, when heat-resistant incombustible fibers are used as the fabric covering the internal structure, the flame retardancy is excellent, but it is extremely expensive.Furthermore, there are problems of workability at the time of opening, hygroscopicity and tactile sensation. There is also a problem that it is difficult to obtain a color pattern with high design properties due to the badness and the poor dyeability.

  Improves the shortcomings of flame retardant materials used in products such as furniture and bedding, has excellent texture, moisture absorption and tactile properties required as general characteristics, and has stable flame retardancy As a raw material, a flame-retardant fiber composite in which a highly flame-retardant halogen-containing fiber added with a large amount of a flame retardant and other fibers that are not flame-retardant has been proposed (Patent Document 1). However, this method adds a large amount of flame retardant, which is disadvantageous in terms of cost and manufacturing process, and may be insufficient in flame retardancy for use in upholstered furniture products. there were. In addition, as a flame retardant material that can be used for work clothes, a flame retardant fiber composite having excellent texture and moisture absorption and high flame retardancy has been proposed by mixing a small amount of organic heat resistant fiber. (Patent Document 2). However, in this method, the organic heat-resistant fibers are generally colored and the whiteness of the fabric is insufficient, and there is a problem in coloring by dyeing, and further, there are separate properties such as halogen-containing fibers and organic heat-resistant fibers. A plurality of fibers had to be compounded, and there was a problem in design. Furthermore, a flame-retardant nonwoven fabric having a bulkiness from fibers that are essentially flame-retardant and halogen-containing fibers has been proposed (Patent Document 3). However, in this method, a high degree of flame retardancy cannot be obtained unless a plurality of fibers having different properties such as fibers that are inherently flame retardant and halogen-containing fibers are used in combination, and the manufacturing process of the product is complicated. In addition, the inherently flame retardant fiber is generally expensive and disadvantageous in terms of cost. There is also a flame-retardant polyester material that is flame-retardant with a glass component (Patent Document 4). However, since the amount of the glass component is remarkably large, there is a problem with high cost and process stability at the time of fiberization, and fiberization has not been achieved.

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

  Therefore, in view of the above-mentioned situation, the present invention is intended to solve the problem that it has high flame retardancy, has good workability, and the original excellent texture and feel of the fiber material are impaired. It is to provide a flame retardant nonwoven fabric having high designability and comfort. Another object of the present invention is to provide upholstered furniture products such as mattresses which are highly flame retardant and have high design and comfort by covering the internal structure with the flame retardant nonwoven fabric.

  As a result of intensive studies to solve the above-mentioned problems, the present inventors have made halogen-containing fibers containing glass components an essential component, and by using cellulosic fibers and / or polyester fibers as necessary. In addition, a flame-retardant nonwoven fabric having excellent self-extinguishing properties, high carbon film forming ability, high designability and comfort, and upholstered furniture products such as flame-retardant mattresses using the same can be obtained. As a result, the present invention has been completed.

That is, the flame-retardant nonwoven fabric according to the present invention has a dry heat shrinkage at 5O <0> C of 5% or less, and contains 15 parts by weight or more of a halogen-containing fiber (A) containing a glass component, and cellulosic fiber (B) 0 It consists of 100 parts by weight in total of 85 parts by weight and 0 to 40 parts by weight of polyester fiber (C), and has a basis weight of 200 g / m ² or more.

  Here, the halogen-containing fiber (A) is 30 to 70% by weight of acrylonitrile, 70 to 30% by weight of halogen-containing vinyl and / or halogen-containing vinylidene monomer, and vinyl monomers 0 to copolymerizable with these. It is preferable that 4 to 50 parts by weight of the glass component is contained with respect to 100 parts by weight of the acrylic polymer composed of 10% by weight.

  Moreover, it is preferable that the glass transition temperature of the said glass component exists in the range of 200-400 degreeC, and it is more preferable that the said glass component contains a phosphorus compound and / or a zinc compound.

  Further, the halogen-containing fiber (A) preferably contains 5 to 50 parts by weight of the glass component and an inorganic additive other than the glass component with respect to 100 parts by weight of the acrylic polymer. Inorganic additives other than glass components include antimony compounds such as antimony trioxide, antimony pentoxide, antimonic acid, antimony oxychloride, natural or synthetic mineral products such as kaolin, zeolite, montmorillonite, talc, bentonite, graphite, Aluminum compounds such as aluminum hydroxide, aluminum sulfate and aluminum silicate, magnesium compounds such as magnesium hydroxide and magnesium oxide, zinc compounds such as zinc oxide, zinc borate, zinc carbonate and zinc stannate, stannic oxide, Metastannic acid, stannous oxyhalide, oxyhalogenated Tin, stannous hydroxide, and more preferably at least one selected from the group consisting of tin compounds such as tin tetrachloride.

  The cellulosic fiber (B) is preferably at least one fiber selected from the group consisting of cotton, hemp, rayon, polynosic, cupra, acetate and triacetate.

  The polyester fiber (C) is preferably a low-melting-point binder fiber, and the low-melting-point binder fiber is a fiber made of a single component of a low-melting polyester, a fiber made of a composite of ordinary polyester and low-melting polyester, More preferably, it is at least one fiber selected from the group consisting of fibers made of a composite of ordinary polyester and low-melting polyolefin.

  In addition, the upholstered furniture product of the present invention is characterized in that the flame retardant nonwoven fabric is used as a fabric covering an internal structure.

  In addition, it is preferable that the upholstered furniture product is a mattress that does not ignite the internal structure in the Technical Bulletin 603 (hereinafter TB603) combustion test in California, USA.

The flame-retardant nonwoven fabric of the present invention has a dry heat shrinkage at 160 ° C. of 5% or less, and contains 15 parts by weight or more of a halogen-containing fiber (A) containing a glass component, and 0 to 85 weights of a cellulose fiber (B). Part, polyester fiber (C) consisting of 0 to 40 parts by weight, and having a basis weight of 200 g / m ² or more, has high flame retardancy, and The processability is good, and the original excellent texture and feel of the fiber material are not impaired, and it has high designability and comfort. Further, the upholstered furniture product of the present invention is highly flame-retardant by covering the internal structure with the flame-retardant nonwoven fabric, and has high design and comfort.

  The flame-retardant nonwoven fabric of the present invention comprises a halogen-containing fiber (A) containing a glass component as an essential component, and optionally contains a cellulose fiber (B) and / or a polyester fiber (C). It is characterized by that.

  The component (A) used in the present invention is a halogen-containing fiber having a dry heat shrinkage at 160 ° C. of 5% or less and containing a glass component (hereinafter, the component (A) is simply referred to as “halogen-containing fiber ( A) ". The halogen-containing fiber (A) is a component that increases the ability to form a carbonized film and the ability to retain the shape of the carbonized film when the flame-retardant nonwoven fabric burns, and also imparts high self-extinguishing properties to the flame-retardant nonwoven fabric. The self-digestibility of the halogen-containing fiber (A) is such that when the surface of the non-woven fabric containing the halogen-containing fiber (A) is exposed to flame, an oxygen-deficient gas, that is, a gas containing non-combustible halogen atoms, such as chlorine gas And hydrochloric acid gas is used to help extinguish the flame on the nonwoven fabric surface.

  Examples of the halogen-containing polymer (that is, the (A) component other than the glass component described later) that is a substrate of the component (A) used in the present invention include, for example, homopolymers and copolymers of halogen-containing monomers such as vinyl chloride and vinylidene chloride. Polymers, monomers copolymerizable with these halogen-containing monomers, such as copolymers with acrylonitrile, styrene, vinyl acetate, acrylate esters, etc., or graft polymers in which halogen-containing monomers are grafted onto PVA polymers However, it is not limited to these. Among these halogen-containing polymers, an acrylic polymer composed of a copolymer of a halogen-containing monomer and acrylonitrile is preferable from the viewpoint of imparting flame retardant fabrics with excellent flame resistance, touch, and design. .

  The acrylic polymer comprises 30 to 70% by weight of acrylonitrile, 70 to 30% by weight of halogen-containing vinyl and / or halogen-containing vinylidene monomer, and 0 to 10% by weight of vinyl monomer copolymerizable therewith. It is preferable that the resulting fiber has a desired performance (strength, flame retardancy, dyeability, etc.) and has a texture of acrylic fiber, 40 to 60% by weight of acrylonitrile, halogen-containing vinyl and / or It is more preferably composed of 60 to 40% by weight of a halogen-containing vinylidene monomer and 0 to 10% by weight of a vinyl monomer copolymerizable therewith.

  Examples of the copolymerizable vinyl monomer include acrylic acid, its ester, methacrylic acid, its ester, acrylamide, methacrylamide, vinyl acetate, vinyl sulfonic acid, its salt, methallyl sulfonic acid, its salt, and styrene. Examples thereof include sulfonic acid, a salt thereof, 2-acrylamido-2-methylsulfonic acid, a salt thereof, and the like, and one or more of them are used. In addition, it is preferable that at least one of them is a sulfonic acid group-containing vinyl monomer because dyeability is improved.

  Specific examples of the copolymer containing units from the halogen-containing vinyl and / or the halogen-containing vinylidene monomer and acrylonitrile include, for example, 50% by weight of vinyl chloride, 49% by weight of acrylonitrile, and 1% by weight of sodium styrenesulfonate. A copolymer comprising 47% by weight of vinylidene chloride, 51.5% by weight of acrylonitrile, 1.5% by weight of sodium styrenesulfonate, 41% by weight of vinylidene chloride, 56% by weight of acrylonitrile, 2-acrylamido-2- Examples thereof include a copolymer comprising 3% by weight of sodium methyl sulfonate. These can be obtained by a known polymerization method such as an emulsion polymerization method, a suspension polymerization method, or a solution polymerization method.

The halogen-containing fiber (A) used in the present invention contains a glass component in addition to the halogen-containing polymer. The glass component is a component that has the effect of further enhancing the ability to form a carbonized film and the ability to maintain the shape of the carbonized film when the flame retardant nonwoven fabric is burned. Examples of the glass component include SiO ₂ —PbO, SiO ₂ —PbO—ZnO, SiO ₂ —B ₂ O ₃ —Na ₂ O, SiO ₂ —B ₂ O ₃ —PbO, and SiO ₂ —Al ₂ O. ₃ system, B ₂ O ₃ —PbO system, B ₂ O ₃ —ZnO system, B ₂ O ₃ —Na ₂ O—PbO system, B ₂ O ₃ —PbO—ZnO system, B ₂ O ₃ —P ₂ O ₅ System, B ₂ O ₃ —Bi ₂ O ₃ —ZnO system, P ₂ O ₅ —ZnO system, etc., among which those containing phosphorus compounds and / or zinc compounds are particularly preferred. It is not limited. Moreover, the glass components as described above may be used singly, and there is no problem even if they are used in combination. The ratio of the glass component is preferably 4 to 50 parts by weight, more preferably 7 to 40 parts by weight, and still more preferably 10 to 30 parts by weight with respect to 100 parts by weight of the halogen-containing polymer. When the ratio of the glass component is less than 4 parts by weight with respect to 100 parts by weight of the halogen-containing polymer, the effect of maintaining the shape of the carbonized film is not sufficient at the time of combustion, making it difficult to obtain the required flame retardancy. When the proportion of the glass component exceeds 50 parts by weight with respect to 100 parts by weight of the halogen-containing polymer, although a sufficient effect of maintaining the shape of the carbonized film is obtained, the flexibility of the fiber is lost and the fiber tends to become brittle. This is not preferable because it causes thread breakage and high costs in the manufacturing process during fiberization.

  The glass transition temperature of the glass component is preferably in the range of 200 to 400 ° C. or less, more preferably 200 to 300 ° C. When the glass transition temperature is less than 200 ° C., it is considered that the melting of the glass component is fast at the time of combustion and the shape retention effect of the carbonized film is easily obtained, but the production of the glass component tends to be difficult. On the other hand, when the glass transition temperature exceeds 400 ° C., the glass component does not melt at the temperature at which the halogen-containing fiber (A) is decomposed during combustion, so that it is difficult to obtain a carbon film forming effect and a carbon film shape maintaining effect.

  The glass component is preferably particulate. By making the glass component into a particulate form, even when the proportion of the glass component in the halogen-containing fiber (A) is increased, the flexibility of the fiber is not easily lost and the fiber is not easily brittle. It does not occur and processability is improved. When the glass component is in the form of particles, the average particle size is 3 μm or less, avoiding troubles such as nozzle clogging in the production process of the halogen-containing fiber (A), improving the strength of the fiber, This is preferable from the viewpoint of the dispersibility of the glass component particles. Further, the glass component has no problem even if the particle surface is chemically modified to improve the blocking property.

  It is preferable that the halogen-containing fiber (A) used in the present invention also contains an inorganic additive other than the glass component. The inorganic additive other than the glass component here is an inorganic compound that does not contain the glass component, for example, antimony compounds such as antimony trioxide, antimony pentoxide, antimonic acid, antimony oxychloride, kaolin, and zeolite. , Montmorillonite, talc, bentonite, natural or synthetic mineral compounds such as graphite, aluminum compounds such as aluminum hydroxide, aluminum sulfate, aluminum silicate, magnesium compounds such as magnesium hydroxide, magnesium oxide, zinc oxide, boric acid Zinc compounds such as zinc, zinc carbonate, zinc stannate, tin compounds such as stannic oxide, metastannic acid, stannous oxyhalide, stannous oxyhalide, stannous hydroxide, tin tetrachloride, etc. Although it can mention, it is not limited to these. The proportion of the inorganic additive other than the glass component is preferably 0 to 46 parts by weight, more preferably 5 to 30 parts by weight, and even more preferably 7 to 20 parts by weight with respect to 100 parts by weight of the halogen-containing polymer. is there. Even if the halogen-containing fiber (A) does not contain any inorganic additive other than the glass component, the shape retention effect of the carbonized film by the glass component can be obtained, but in order to obtain a more advanced shape retention effect of the carbonized film It is preferable to add 5 parts by weight or more of an inorganic additive other than the glass component with respect to 100 parts by weight of the halogen-containing polymer. In addition, when the inorganic additive other than the glass component exceeds 46 parts by weight with respect to 100 parts by weight of the halogen-containing polymer, a sufficient shape retention effect of the carbonized film can be obtained, but in the manufacturing process during fiberization. This is not preferable because it causes thread breakage.

  The halogen-containing synthetic fiber (A) used in the present invention has a dry heat shrinkage at 160 ° C. of 5% or less. The dry heat shrinkage referred to here is a sample fineness of 3333 dtex, a sample length of 5 mm, a load of 18 mN, a heating rate of 3 ° C./min, and a nitrogen atmosphere measured by Seiko Electronics Co., Ltd. TMA / SS150C. The shrinkage rate at 160 ° C. When the shrinkage rate at 160 ° C. exceeds 5%, when the flame-retardant nonwoven fabric is exposed to flame, the halogen-containing fiber (A) undergoes thermal shrinkage before the flame-retardant nonwoven fabric forms a carbonized film due to its heat. As a result, a uniform carbonized film cannot be formed. Further, depending on the intensity of the flame when the flame-retardant nonwoven fabric is exposed to the flame, a hole is not formed in the carbonized film, and the flame shielding performance cannot be sufficiently exhibited.

  Here, the flame-shielding property means that when the surface of the flame-retardant nonwoven fabric is exposed to flame, the flame-retardant nonwoven fabric is carbonized while maintaining the form of the fiber so that the flame is shielded and exposed to the flame. It is to prevent the flame from moving to the opposite side of the surface. Specifically, in upholstered furniture products such as mattresses, the upholstered furniture products were exposed to disaster by using the flame retardant nonwoven fabric of the present invention as a fabric covering internal structures such as urethane foam and stuffed cotton. In this case, it is possible to prevent the internal structure from igniting a flame and to prevent combustion to a minimum.

  The halogen-containing fiber (A) used in the present invention is produced by a known production method such as a wet spinning method, a dry spinning method, or a semi-dry semi-wet method. For example, in the wet spinning method, the halogen-containing polymer is dissolved in a solvent such as N, N-dimethylformamide, N, N-dimethylacetamide, acetone, or a rhodan salt aqueous solution, and then a glass component is added to form a spinning stock solution. The stock solution is solidified by extruding it through a nozzle into a coagulation bath, then washed with water, dried, stretched and heat treated, and if necessary, crimped and cut. The halogen-containing fiber (A) used in the present invention may be a short fiber or a long fiber, and can be appropriately selected in the method of use. For example, the halogen-containing fiber (A) is combined with other natural fibers and chemical fibers for processing. Those similar to the fibers are preferable, and short fibers having a length of about 1.7 to 12 dtex and a cut length of about 38 to 128 mm are preferable in accordance with other natural fibers and chemical fibers used for textile products.

  The cellulosic fiber (B) used in the present invention is an important component for maintaining the strength of the flame-retardant nonwoven fabric, and is excellent in texture and hygroscopicity, giving comfort, and forming a carbonized film during combustion. It is a component having Specific examples of the cellulosic fiber (B) include cotton, hemp, rayon, polynosic, cupra, acetate, and triacetate. These may be used alone or in combination of two or more. . In particular, cotton, hemp, and rayon fibers are preferable from the viewpoint of texture and hygroscopicity.

  The polyester fiber (C) used in the present invention is a component for imparting excellent texture, touch, design, product strength and durability to the flame retardant nonwoven fabric of the present invention. In addition, the polyester fiber (C) itself is flammable, but the melt produced during combustion covers the carbide produced by the combustion of the halogen-containing fiber (A) or the cellulose fiber (B), thereby forming a carbonized film. There is an effect to make it strong. Moreover, it becomes easy to make a nonwoven fabric bulky by making the flame-retardant nonwoven fabric of this invention contain a polyester fiber (C).

  Moreover, it is also possible to use a polyester-type low melting-point binder fiber as a polyester-type fiber (C). 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 composed of polyester and low-melting-point polyester or low-melting-point polyolefin. Examples of the low melting point polyolefin include low melting point propylene and low melting point polyethylene. Generally, the melting point of low-melting polyester is approximately 110 to 200 ° C, the melting point of low-melting polypropylene is approximately 140 to 160 ° C, and the melting point of low-melting polyethylene is approximately 95 to 130 ° C. There is no particular limitation as long as it has the ability. Examples of the low-melting-point binder fiber include Safmet (4.4 dtex × 51 mm, melting temperature 110 ° C.) manufactured by Toray Industries, Inc., but is not limited thereto.

  The flame retardant nonwoven fabric 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 even if coloring or dyeing is performed. These may be contained in the halogen-containing fiber (A), the cellulose fiber (B), and the polyester fiber (C) itself, or may be added after forming a nonwoven fabric.

  The flame-retardant nonwoven fabric of the present invention is suitably used as a fabric covering an internal structure in upholstered furniture products such as mattresses.

  As a method for producing a flame-retardant nonwoven fabric, general hot melt bonding methods, chemical bond methods, water jet methods, needle punch methods, stitch bond methods, and the like can be adopted. Is created by applying the web to a nonwoven fabric manufacturing apparatus. In view of the simplicity of the apparatus, the needle punch method is preferable, and if the low melting point binder fiber is used as the polyester fiber (C), it is preferable because the production by the hot melt bonding method is simple and the productivity is high. It is not limited.

The flame-retardant nonwoven fabric of the present invention has a basis weight of 200 g / m ² or more from the viewpoint of flame shielding properties. When the basis weight is less than 200 g / m ² , for example, when exposed to intense flames such as the TB603 combustion test in California, USA, it is difficult to maintain the shape and it is difficult to exert flame shielding performance.

  The flame-retardant nonwoven fabric of the present invention comprises 15 parts by weight or more of halogen-containing fibers (A), 0 to 85 parts by weight of cellulose fibers (B), and 0 to 40 parts by weight of polyester fibers (C). Mixing ratio is water absorption, texture, moisture absorption, touch, design, product strength, washing resistance, durability, as well as the flame resistance required for upholstered furniture products made from the resulting flame retardant nonwoven fabric In accordance with the quality, etc., it is appropriately determined within the above range. Preferably, the halogen-containing fiber (A) is 15 to 85 parts by weight, the cellulose fiber (B) is 0 to 85 parts by weight, and the polyester fiber (C) is 0 to 40 parts by weight. To be compounded. More preferably, the halogen-containing fiber (A) is 20 to 60 parts by weight, the cellulosic fiber (B) is 10 to 75 parts by weight, and the polyester fiber (C) is 10 to 30 parts by weight. Combine to be. When the hot melt bonding method is selected during the production of the nonwoven fabric, it is preferable that the polyester fiber (C) contains at least 10 parts by weight of a polyester low-melting-point binder fiber.

  If the proportion of the halogen-containing fiber (A) is less than 15 parts by weight, the carbon film forming ability is insufficient to prevent the flame from igniting internal structures used for bedding and furniture when exposed to intense flames for a long time. Thus, since the self-extinguishing property is also lowered, it is difficult to obtain the required high flame retardancy.

  When the proportion of the cellulosic fiber (B) exceeds 85 parts by weight in 100 parts by weight of the flame-retardant nonwoven fabric, the carbonized film is formed, but the proportion of the halogen-containing fiber (A) is inevitably reduced. Therefore, the form retention ability after the flame-retardant nonwoven fabric is burned and carbonized is lowered, and as a result, the flame retardancy of the nonwoven fabric is lowered, which is not preferable.

  When the proportion of the polyester fiber (C) exceeds 40 parts by weight of 100 parts by weight of the flame retardant nonwoven fabric, the area of the melted portion caused by the combustion of the polyester fiber (C) with respect to the carbonized film increases. Since flame retardance falls, it is not preferable.

  The flame-retardant nonwoven fabric of the present invention thus formed has high flame retardancy, good workability, and the original excellent texture and feel of the fiber material are not impaired, and a high design And comfort.

  The upholstered furniture product of the present invention uses the flame-retardant nonwoven fabric as a fabric covering the internal structure.

  Upholstered furniture products include but are not limited to bedding such as mattresses and furniture such as chairs and sofas.

  Examples of the mattress include, but are not limited to, a pocket coil mattress and a box coil mattress in which a metal coil is used.

  In addition, the furniture includes a tool, a bench, a side chair, an arm chair, a lounge chair / sofa, a seat unit (sectional chair, a separate chair), a rocking chair, a folding chair, a stacking chair, and a chair that are used indoors. In addition, for example, automobile seats, marine seats, aircraft seats, railroad seats, and the like that are used outdoors for vehicle seats and the like can be mentioned.

  Examples of the internal structure include, but are not limited to, resin foams such as polyurethane foam and polystyrene foam, batting, and nonwoven fabric. In addition, the batting here is a concept that means a structure of a fiber-based material used inside the upholstered furniture product, and does not particularly mean cotton.

  As the fabric covering the internal structure, only one flame retardant nonwoven fabric of the present invention may be used, or two or more fabrics including at least one flame retardant nonwoven fabric of the present invention may be used in an overlapping manner. Good. That is, when two or more fabrics covering the internal structure are used, other fabrics may be used as conventional fabrics as long as at least one flame-retardant nonwoven fabric of the present invention is included.

  The flame-retardant nonwoven fabric used in the upholstered furniture product of the present invention may be used as a side surface for forming the surface of the upholstered furniture product, or may be sandwiched between the side surface and an internal structure such as polyurethane foam. . Here, the side ground in the present invention refers to the outermost fabric among the fabrics covering the internal structure, and when two or more fabrics covering the internal structure are used, the side fabric is positioned on the outermost side. The fabric that forms the surface layer of upholstered furniture products. If only one piece of fabric covering the internal structure is used, the flame retardant nonwoven fabric will replace the conventional side. In addition, when using a flame retardant nonwoven fabric sandwiched between the side fabric and the internal structure, the side fabric is used as a conventional fabric, and a flame retardant nonwoven fabric is sandwiched between the fabric and the internal structure. Alternatively, the flame retardant nonwoven fabric may be used as the side fabric, and two flame retardant nonwoven fabrics may be used in an overlapping manner. When using a flame retardant nonwoven fabric sandwiched between the side ground and the internal structure, it is a matter of course that the entire internal structure is covered with the flame retardant nonwoven fabric and then covered with the side ground.

In the upholstered furniture product of the present invention, by making the fabric covering the internal structure non-woven fabric, unlike woven fabric and knitted fabric, it is not necessary to create yarn by spinning and fabric can be created directly from cotton, so the mixing ratio of materials Has a high degree of freedom. In addition, since the nonwoven fabric has elasticity compared to the woven fabric, the carbonized film formed at the time of combustion is less likely to crack.
Such upholstered furniture products have excellent properties of flame retardant nonwoven fabrics, that is, excellent flame retardancy, good workability, and excellent texture and feel inherent to fiber materials. It is not damaged and has high designability and comfort.

  Moreover, the mattress using the said flame-retardant nonwoven fabric as a cloth | cover which covers an internal structure does not produce fire spread to an internal structure in the US TB603 combustion test.

  The reason why the flame retardant nonwoven fabric containing the halogen-containing fiber (A), the cellulosic fiber (B), and the polyester fiber (C) in the above-described ratio exhibits excellent flame shielding properties is as follows. Conceivable. When the flame-retardant nonwoven fabric is exposed to flame, as described above, the non-flammable gas is generated from the halogen-containing fiber (A), and the glass component contained in the halogen-containing fiber (A) is melted to generate flammability. By suppressing the surface diffusion of the property gas, combustion of the nonwoven fabric is suppressed (self-extinguishing property). The molten glass component is an inorganic additive other than the glass component contained in the carbide or halogen-containing fiber (A) produced by combustion of the halogen-containing fiber (A), cellulose-based fiber (B), or polyester-based fiber (C). By entering and solidifying between the agents, the generated carbide forms a strong carbonized film without burning out or burning. Moreover, since the halogen-containing fiber (A) has a low shrinkage rate with respect to heat, the formed carbonized film is less prone to cracks and holes (carbonization effect, shape retention effect). As a result, the flame retardant nonwoven fabric of the present invention retains the form of the carbonized film formed without disintegrating after combustion, thus preventing the flame from moving to the surface opposite to the surface exposed to the flame. In addition, it exhibits a high level of flame shielding that prevents further spread of fire.

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

(Flame retardance evaluation method)
(1) Preparation of simple mattress for flame retardancy evaluation test After halogen-containing fiber (A), cellulosic fiber (B), and polyester fiber (C) are mixed at a predetermined ratio and opened with a roller card, A nonwoven fabric having a length of 45 cm and a width of 30 cm was prepared by a hot melt bonding method. A three-layer structure in which a polyester non-woven fabric of the same size (weighing 300 g / m ² ) is layered on the non-woven fabric, and further a polyester fabric (weighing 120 g / m ² ) is quilted with a cotton thread, and is 30 cm long × horizontal It was fixed on a 45 cm × thickness 7.5 cm, density 22 kg / m ³ polyurethane foam (type 360S manufactured by Toyo Tire & Rubber Co., Ltd.) using a stapler so that the side fabric would be the polyester fabric.

(2) Flame Retardancy Evaluation Test Method Of the bed mattress combustion test method TB603 of California, USA, the test was performed according to the bed mattress top surface test method. That is, a T-shaped burner was set horizontally at a position 39 mm from the top surface of the simple mattress for flame retardancy evaluation test, and propane gas was used as the combustion gas under the conditions of a gas pressure of 101 KPa and a gas flow rate of 12.9 L / min. Indirect flame for 70 seconds. At this time, if the carbonized film of the nonwoven fabric has no thickness spots, no holes or cracks, and self-extinguishes, there is no flame to the urethane foam inside. ○ If there are no holes or cracks, and self-extinguish, and there is no flame on the internal urethane foam, there is a small hole in the carbonized film or a small crack that penetrates, but self-extinguishes to the internal urethane foam The evaluation was carried out with Δ when there was no flame, and x when there was a small hole in the carbonized film or a small crack penetrating the flame and the urethane foam was flared before self-extinguishing. In addition, regardless of the presence or absence of perforation and cracking of the carbonized film and the presence or absence of flame on the internal urethane foam, the flame that flamed on the top surface of the test mattress moves to the side and still extinguishes itself. When there was no, all were set as x.
Among the evaluation results, ◎ or ○ was “pass” and Δ or × was “fail”.

(Method for measuring dry heat shrinkage of halogen-containing fiber (A))
By measuring the obtained halogen-containing fiber (A) with TMA / SS150C manufactured by Seiko Denshi Kogyo Co., Ltd., sample fineness of 3333 dtex, sample length of 5 mm, load of 18 mN, heating rate of 3 ° C./min, in a nitrogen atmosphere, The dry heat shrinkage at 160 ° C. was determined.

(Production Examples 1 to 7 of halogen-containing fiber (A))
A copolymer comprising 51% by weight of acrylonitrile, 48% by weight of vinylidene chloride and 1% by weight of sodium p-styrene sulfonate (halogen content: 35% by weight) was dissolved in acetone so that the resin concentration was 30%. With respect to 100 parts by weight of the resin component in the obtained resin solution, a predetermined glass component (P ₂ O ₅ —ZnO glass, glass transition temperature 240 ° C. Asahi Fiber Glass ZP450) and an inorganic additive (aluminum hydroxide, and Antimony trioxide) was added at the ratio shown in Table 1 to prepare a spinning dope. A spinning solution containing a glass component, aluminum hydroxide and antimony trioxide was extruded into a 40% acetone aqueous solution using a nozzle having a nozzle hole diameter of 0.10 mm and a hole number of 1000 holes, washed with water, dried at 120 ° C., and then 150 After stretching 3 times at ° C., heat treatment was performed for 1 minute at the temperature shown in Table 1, and further cut to a cut length of 64 mm to obtain a halogen-containing fiber (A). The obtained fiber was a short fiber having a fineness of 7.8 dtex.

  Table 1 shows Production Examples 1 to 7 of the halogen-containing fiber (A) and measurement results of the dry heat shrinkage at 160 ° C.

(Examples 1-8, Comparative Examples 1-9)
Toray (A) containing halogen-containing fibers (A), rayon fibers (B) (1.5 dtex, cut length 38 mm), polyester-based low-melting-point binder fibers (C) prepared in Production Examples 1 to 4 of halogen-containing fibers (A) Create a simple mattress according to the method for creating a simple mattress for flame retardancy evaluation test, using a non-woven fabric in which SAFMET (4.4 dtex × 51 mm, melting temperature 110 ° C.) manufactured by Co., Ltd. has a predetermined ratio, Flame retardant evaluation was performed. The results are shown in Table 2.

  In Examples 1-8, the flame retardancy test results are good, and the flame retardant nonwoven fabric used has no cracks or perforations even after the completion of the combustion test, and forms a good carbonized film. Flame retardant on the urethane foam was prevented. On the other hand, in Comparative Examples 1, 3, and 5, since the proportion of the halogen-containing fiber (A) is low, a good carbonized film cannot be formed, and perforations are generated in the nonwoven fabric. I burned and failed. In Comparative Examples 2, 4, and 6, since the ratio of the polyester fiber (C) was high, the polyester fiber portion was melted and perforated, and the urethane foam as the internal structure was flared and failed. In Comparative Examples 7 to 9, since the halogen-containing fiber (A) does not contain a glass component, a good carbonized film cannot be formed, and perforations are generated in the nonwoven fabric. Passed.

(Comparative Examples 10-17)
Halogen-containing fibers (A) produced in Production Examples 1 to 3 of the halogen-containing fibers (A), rayon fibers (B) (1.5 dtex, cut length 38 mm), polyester-based low melting point binder fibers (C) Toray ( Create a simple mattress according to the method for creating a simple mattress for flame retardancy evaluation test, using a non-woven fabric in which SAFMET (4.4 dtex × 51 mm, melting temperature 110 ° C.) manufactured by Co., Ltd. has a predetermined ratio, Flame retardancy evaluation was performed based on the flame retardancy evaluation method. The results are shown in Table 3 together with the results of Examples 1-8.

  In Comparative Examples 10 to 17, the proportions of the components (A) to (C) constituting the nonwoven fabric were the same as those in Examples 1 to 8, but a good carbonized film could not be formed due to the low basis weight of the nonwoven fabric. In particular, in Comparative Examples 10 to 14 and 16, the urethane foam as an internal structure was flared and failed. In Comparative Examples 15 and 17, flame retardant of the urethane foam of the internal structure was avoided, but cracks occurred in the carbonized film, and the flame shielding properties were greatly inferior compared with Examples 6 and 8.

(Comparative Examples 18-25)
Halogen-containing fibers (A) produced in Production Examples 5 to 7 of the halogen-containing fibers (A), rayon fibers (B) (1.5 dtex, cut length 38 mm), polyester-based low melting point binder fibers (C) Toray ( Create a simple mattress according to the method for creating a simple mattress for flame retardancy evaluation test, using a non-woven fabric in which SAFMET (4.4 dtex × 51 mm, melting temperature 110 ° C.) manufactured by Co., Ltd. has a predetermined ratio, Flame retardancy evaluation was performed based on the flame retardancy evaluation method. The results are shown in Table 4 together with the results of Examples 1-8.

  In Comparative Examples 18 to 25, since the halogen-containing fiber (A) has a high dry heat shrinkage rate at 160 ° C., the halogen-containing fiber (A) shrinks before being carbonized when exposed to the flame of a burner. A carbonized film could not be formed. In particular, in Comparative Examples 18, 22, and 24, the urethane foam, which is an internal structure, flared and failed. In Comparative Examples 19, 20, 21, 23, and 25, the flame of the internal structure on the urethane foam was avoided, but small holes were formed in the carbonized film at several locations due to the pressure of the burner. , 8 was significantly inferior in flame shielding and was rejected.

(Comparative Examples 26-27)
Instead of the halogen-containing fiber (A) and rayon fiber (B), Visil (fineness 1.7 dtex, cut length 40 mm) manufactured by Sateri, which is a silicic acid-containing rayon fiber, is used, and polyester A simple mattress for flame retardant evaluation test using a non-woven fabric having a predetermined ratio of Safmet (4.4 dtex × 51 mm, melting temperature 110 ° C.) manufactured by Toray Industries, Inc., which is a low melting point binder fiber (C) A simple mattress was prepared in accordance with the created flame retardant evaluation method, and the flame retardant evaluation was performed based on the flame retardant evaluation method. The results are shown in Table 5 together with the results of Examples 1-8.

In Comparative Examples 26 and 27, a good carbonized film was formed as in Examples 1 to 8, but the self-extinguishing performance was completely insufficient, and the flame passed to the side surface through the upper surface of the simple mattress for flame retardancy evaluation test. Moved, and still did not extinguish, so forced fire extinguishing was performed at the time shown in Table 5, and thus it was unacceptable. In addition, when Visil is used, thread breakage occurs in a large amount in the roller card as compared with the case where the halogen-containing fiber (A) is used, and the fiber card is crushed into a fine powder having a length of several millimeters. There was also a problem in processability, such as the generation of fibers that scattered and mixed into the nonwoven fabric.

Claims (11)

15% by weight or more of halogen-containing fiber (A) having a dry heat shrinkage at 160 ° C. of 5% or less and containing a glass component, 0 to 85 parts by weight of cellulose fiber (B), and polyester fiber (C) A flame-retardant nonwoven fabric comprising 100 parts by weight in total of 0 to 40 parts by weight and having a basis weight of 200 g / m ² or more.   The halogen-containing fiber (A) is 30 to 70% by weight of acrylonitrile, 70 to 30% by weight of halogen-containing vinyl and / or halogen-containing vinylidene monomer, and 0 to 10% by weight of vinyl monomer copolymerizable therewith. The flame-retardant nonwoven fabric according to claim 1, wherein the glass component is contained in an amount of 4 to 50 parts by weight per 100 parts by weight of the acrylic polymer.   The flame-retardant nonwoven fabric according to claim 1 or 2, wherein a glass transition temperature of the glass component is in a range of 200 to 400 ° C.   The flame-retardant nonwoven fabric according to any one of claims 1 to 3, wherein the glass component contains a phosphorus compound and / or a zinc compound.   The halogen-containing fiber (A) contains 5 to 50 parts by weight in total of the glass component and an inorganic additive other than the glass component with respect to 100 parts by weight of the acrylic polymer. The flame-retardant nonwoven fabric as described in crab.   Inorganic additives other than the glass component include antimony compounds such as antimony trioxide, antimony pentoxide, antimonic acid, and antimony oxychloride, natural or synthetic mineral products such as kaolin, zeolite, montmorillonite, talc, bentonite, and graphite. Aluminum compounds such as aluminum hydroxide, aluminum sulfate and aluminum silicate, magnesium compounds such as magnesium hydroxide and magnesium oxide, zinc compounds such as zinc oxide, zinc borate, zinc carbonate and zinc stannate, stannic oxide And at least one selected from the group consisting of tin compounds such as metastannic acid, stannous oxyhalide, stannous oxyhalide, stannous hydroxide, and tin tetrachloride. 5. The flame-retardant nonwoven fabric according to 5.   The flame-retardant nonwoven fabric according to claim 1, wherein the cellulosic fiber (B) is at least one fiber selected from the group consisting of cotton, hemp, rayon, polynosic, cupra, acetate and triacetate.   The flame-retardant nonwoven fabric according to claim 1, wherein the polyester fiber (C) is a low-melting-point binder fiber.   The low melting point binder fiber is at least selected from the group consisting of a fiber composed of a single component of a low melting point polyester, a fiber composed of a composite of a normal polyester and a low melting point polyester, and a fiber composed of a composite of a normal polyester and a low melting point polyolefin. The flame-retardant nonwoven fabric according to claim 8, which is a single fiber.   The upholstered furniture product which used the flame-retardant nonwoven fabric in any one of Claims 1-9 as a fabric which covers an internal structure. The upholstered furniture product according to claim 10, which is a mattress that does not ignite an internal structure in a combustion test of Technical Bulletin 603 (hereinafter referred to as TB603), California, USA.