JP4351220B2 - Rugous gas rug and its manufacturing method - Google Patents

Description

  The present invention relates to a rug, and more particularly to a rugged flame generating rug that is flame resistant and flame retardant, and that hardly generates harmful gas even when heated. In addition, the toxic gas difficulty generating rug in the present invention refers to a rug certified by the test method of the smoke generation and combustion toxicity test.

  In order to reduce the damage caused by the fire as much as possible, flame retardant and fire resistant materials are used for houses, furniture, rugs and the like.

  However, the house, furniture, rugs, etc. are heated by the fire, and harmful gas is generated, and since this harmful gas has been inhaled, it is impossible to escape from the fire site, resulting in death or injury. There are many human damages. Therefore, it is desired to use a flame retardant fire resistant material that does not generate harmful gases. In particular, when a fire breaks out in a place where there is no escape, such as a ship, it develops into a major disaster with many casualties and falls into a serious situation. In addition to flame resistance and fire resistance, flame resistance and harmful gases There are strict standards for outbreaks.

  Accordingly, the present inventor has developed a rug that is excellent in flame resistance as well as flame retardancy and fire resistance and hardly generates harmful gases.

The rugged gas generation rug according to the present invention is a non-woven fiber assembly in which a backing material layer and a skin material layer are bonded through an adhesive layer, and the backing material layer is a mixture of oxidized acrylic fiber and polyester fiber. The blending ratio is 30 to 80% of oxidized acrylic fiber and 20 to 70% of polyester fiber, and the adhesive layer is made of multifilament yarn of polyester fiber. It consists of an amorphous olefin polymer composition in which a plain weave mesh is embedded, and the outer skin layer is made of a polyester fiber nonwoven fabric, and a pile is formed with a pile yarn of 100% wool, and its back surface An adhesive composed of an amorphous olefin polymer composition for preventing yarn dropout is applied to the surface, and a liquid incombustible material is adhered to the surface of the skin material layer. Than is.

  If comprised as mentioned above, the whole raw material will be a thing of the material which does not generate | occur | produce a harmful gas easily, and it will have flame resistance as well as flame retardance and fire resistance.

  Moreover, since the backing material layer contains one or both of polyester-based fibers and aramid fibers, the heat setting property is improved and the density is increased, so that the strength as the backing material is increased.

Furthermore, since the adhesive layer is made of an amorphous olefin polymer composition containing a plain woven mesh fabric made of polyester fiber multifilament yarn , the adhesiveness is good, the dimensional stability is high, and the durability is high. Increase.

  Furthermore, since the skin material layer is formed by forming a pile with a pile yarn of 100% wool on the surface of the primary base fabric made of a polyester fiber nonwoven fabric, and applying an adhesive for preventing thread dropout on the back surface thereof, Since a skin material layer rich in cushioning properties is obtained and the entire skin material layer is firmly integrated, thread dropout and breakage are unlikely to occur.

  Moreover, since a liquid flame retardant is made to adhere to the surface of a skin material layer, a nonflammability improves further and a flame retardance, fire resistance, and flame resistance improve further.

  In addition, the manufacturing method of the noxious gas difficulty generation rug which concerns on this invention is manufactured by the following process AC.

  A. Forming a backing material consisting of a non-woven fiber assembly in which polyester fibers and / or aramid fibers are mixed and entangled with mixed fibers of either oxidized acrylic fibers or carbon fibers or both. To do. Therefore, the types of fibers constituting the backing material are oxidized acrylic fibers + polyester fibers, oxidized acrylic fibers + aramid fibers, carbon fibers + polyester fibers, carbon fibers + aramid fibers, oxidized acrylic fibers + carbon fibers + polyester fibers. Fiber, oxidized acrylic fiber + carbon fiber + aramid fiber, oxidized acrylic fiber + polyester fiber + aramid fiber, carbon fiber + polyester fiber + aramid fiber, oxidized acrylic fiber + carbon fiber + polyester fiber + aramid fiber It becomes a combination.

  B. An adhesive comprising a non-woven fabric made of polyester fiber as a primary base fabric, a pile is formed with a pile yarn of 100% wool on the surface of the primary base fabric, and an amorphous olefin polymer composition is formed on the back surface thereof to prevent the thread from coming off. Is applied to form a skin material in which a liquid incombustible material is adhered to the pile surface.

C. The above backing material is coated with a paste of amorphous olefin polymer composition, and a plain woven mesh fabric composed of multifilament yarns of polyester fiber is overlaid, and this is heated to form an amorphous olefin polymer composition. The pasty material is melted, the above skin material is overlaid on it, and after pressurizing it, it is heated to stabilize the shape and dimensions. The pasty body of the combined composition is solidified to bond the backing material and the skin material, and cut into a predetermined size.

  According to the present invention, it is possible to provide a rug that has not only flame resistance and fire resistance, but also sufficient flame resistance and hardly generates harmful gases.

  Hereinafter, embodiments of the present invention will be described in detail with reference to the accompanying drawings.

  FIG. 1 is a partially cutaway perspective view of a rug according to the present embodiment, FIG. 2 is a schematic cross-sectional view of the rug according to the present embodiment, and FIG. 3 shows a manufacturing process of the rug according to the present embodiment. FIG.

  1 and 2, A represents a rug according to this embodiment, and the rug A is configured by bonding a backing material layer 10 and a skin material layer 20 via an adhesive material layer 30.

  The backing material layer 10 is a non-woven fiber assembly composed of oxidized acrylic fibers and polyester fibers (including thermally adhesive fibers).

  The oxidized acrylic fiber used for the backing material layer 10 is obtained by heat-treating a polyacrylonitrile (PAN) -based precursor fiber (precursor) in an oxidizing atmosphere. When this oxidized acrylic fiber is used, even if it ignites, the damage of the backing material itself due to combustion and melting is slight. In addition, since the oxidized acrylic fiber has appropriate strength and elongation, a non-woven fiber assembly can be formed in the manufacturing process.

  The non-woven fiber assembly in this example uses a mixture of polyester fiber and the above oxidized acrylic fiber in order to enhance the heat setting property. In this way, in the manufacturing process, heat setting is improved by shrinking entanglement of the polyester fiber by heating in the post-needling process, followed by pressure cooling, so that the density after pressing is kept high and dimensional stability is maintained. Flame retardancy can be enhanced along with the properties. Since the above-mentioned oxidized acrylic fiber alone does not have sufficient rigidity, it is difficult to maintain a high density state by itself, and the non-woven fiber aggregate is maintained at a required density by blending polyester fibers having high rigidity. Excellent performance as a backing material. As described above, when polyester fibers (including heat-adhesive fibers) are used, sufficient heat setting properties can be obtained and the heat resistance of the backing material can be avoided because it has a relatively high heat resistance. A backing material having a relatively high heat resistance such as a heat resistant temperature of 150 ° C. to 200 ° C. can be obtained. In this embodiment, polyester fibers are used as the fibers mixed with the oxidized acrylic fibers, but aramid fibers may be used instead.

  The blending ratio of the oxidized acrylic fiber and the polyester fiber is desirably a weight ratio of 30 to 80% for the oxidized acrylic fiber and 20 to 70% for the polyester fiber. When the blending ratio of the polyester fiber is suppressed to such a level, a backing material can be obtained in which the heat setting property is remarkably improved without greatly reducing the flame resistance.

  If the backing material layer 10 of the rug A is configured using the backing material as described above, it has high flame resistance and flame resistance, so that no harmful gas is generated even if it is directly exposed to flame. In addition, since it does not burn by self-extinguishing instantaneously, it does not burn, so that even if an ignition occurs, damage due to combustion / melting of the backing material itself is minimal.

  The adhesive material layer 30 is made of a harmful gas difficulty generating material made of an amorphous olefin polymer composition 32 in which a mesh base 31 made of a multifilament yarn of polyester fiber is contained. Amorphous olefin polymer composition is an adhesive material that generates less toxic gas when burned, and together with the amorphous olefin polymer, crystalline polypropylene as a secondary polymer, tackifier, melt viscosity reducing agent, and filling A composition containing an agent is preferable, and various additives such as a flame retardant and a colorant may be blended as necessary. Examples of the amorphous olefin polymer include APAO (amorphous polyolefin), APP (amorphous polypropylene), and amorphous butene polymer. In addition to the amorphous olefin polymer of the main polymer, the polymer composition may contain other resin components having no halogen element such as crystalline polypropylene as a secondary polymer. In addition to the secondary polymer, various additives such as a tackifier such as an aliphatic petroleum resin, a melt viscosity reducing agent such as a wax, various fillers, various flame retardants may be mixed as necessary. .

  Since the polyester fiber contained in the adhesive layer 30 has a high tensile strength and is difficult to stretch, a rug A having high strength and excellent dimensional stability can be obtained.

  In addition, by using a plain weave made of polyester filament multifilament yarn as the mesh base 31, high strength and dimensional stability can be obtained in both vertical and horizontal directions.

In the present embodiment, although is more inherent mesh fabric 31 made of multi-filament yarns of polyester fiber in the adhesive layer 30 is not limited thereto, internalized the mesh locations plurality of layers bonded You may comprise an agent layer.

  When the adhesive layer of the rug A is constituted as described above, the adhesiveness is good due to the amorphous olefin polymer composition 32, and the tensile strength is large due to the mesh base 31 composed of multifilament yarns of polyester fibers, A rug A having good dimensional stability and increased durability is obtained.

  In the skin material layer 20, a pile 22 is formed of a pile yarn of 100% wool on the surface of a primary base fabric 21 made of a polyester fiber nonwoven fabric, and an amorphous olefin polymer composition is used on the back surface thereof to prevent the thread from coming off. It is a rug living machine made of a harmful gas difficult-to-generate material to which an adhesive 23 is applied. A liquid incombustible material is attached to the surface of the skin material layer 20 by spraying.

  As described above, when the skin material layer 20 of the rug A is formed, a skin material layer rich in cushioning properties is obtained, and the entire skin material layer is firmly integrated. In addition, nonflammability is further improved, and flame retardancy, fire resistance and flame resistance are improved.

  Next, a process of manufacturing the rug A of this embodiment by bonding the backing material layer 10 and the skin material layer 20 configured as described above via the adhesive material layer 30 will be described.

  First, a pile 22 is formed from a pile yarn of 100% wool on the surface of a primary base fabric 21 made of a polyester fiber nonwoven fabric, and an adhesive 23 made of an amorphous olefin polymer composition is formed on the back surface thereof to prevent the yarn from coming off. Is prepared, and a skin material 20 having a liquid incombustible material attached to the surface is prepared.

  And the backing material 10 which consists of an elongate nonwoven fiber assembly which consists of 30-80 weight% of the above-mentioned oxidized acrylic fiber and 20-70 weight% of polyester fibers is mounted on a belt conveyor, and the left from the figure right Transport at a constant speed in the direction.

Next, the above-mentioned backing material 10 on a belt conveyor is coated with the paste-like body of the amorphous olefin polymer composition 32, and the mixture is leveled with a doctor knife. A mesh ground 31 made of polyester fiber is superposed on the paste of the amorphous olefin polymer composition 32 that has been leveled to a certain amount, and the amorphous olefin coated on the backing material 10 using a heating device. The pasty body of the polymer composition 32 is heated and melted. A plurality of layers of mesh fabric made of multifilament yarn of polyester fiber may be superposed.

  On the heated and melted amorphous olefin polymer composition 32, the above-prepared skin material 20 is pressed with a pressure roll while being overlaid.

  Thereafter, the polymer is passed through a dryer apparatus and heated to stabilize the dimensions. The amorphous olefin polymer melted with a cooling roll after being pressurized with a pressure roll again in the dryer apparatus and cooled with a cooling device. The paste-like body of the composition 32 is solidified. Moreover, it cuts into tile rug size with a cutting machine as needed.

  The toxic gas flame generating rug according to the present invention is excellent in flame retardancy, fire resistance and flame resistance, so that fire prevention of ships, airplanes, automobiles, etc. as well as places where fire is handled in ordinary households, as well as factories where fires occur. Suitable for vehicles with severe standards.

It is a partially cutaway perspective view of a rug according to an embodiment of the present invention. It is a schematic sectional drawing of the rug concerning the example of the present invention.

Explanation of symbols

A ... Rug 10 ... Backing material layer 20 ... Skin material layer 21 ... Primary base fabric 22 ... Pile 23 ... Adhesive 30 ... Adhesive material layer 31 ... Mesh 32 ... Amorphous olefin Polymer composition

Claims (2)

The backing material layer and the skin material layer are bonded via an adhesive layer,
The backing material layer is a non-woven fiber assembly in which oxidized acrylic fibers and polyester fibers are mixed, and the blending ratio is 30 to 80% of oxidized acrylic fibers and 20 of polyester fibers in weight ratio. ~ 70%,
The adhesive layer is made of an amorphous olefin polymer composition containing a plain weave mesh fabric made of multifilament yarns of polyester fibers,
An adhesive comprising an amorphous olefin polymer composition for forming a pile with a pile yarn of 100% wool on the surface of a primary base fabric comprising a non-woven fabric made of polyester fiber as the skin material layer and preventing the yarn from coming off on the back surface A rugged gas generating rug, wherein a liquid incombustible material is adhered to the surface of the skin material layer. A backing made of a non-woven fiber assembly in which oxidized acrylic fiber and polyester fiber are mixed and entangled in a weight ratio of 30 to 80% oxidized acrylic fiber and 20 to 70% polyester fiber. Forming the material,
An adhesive comprising a non-woven fabric made of polyester fiber as a primary base fabric, a pile is formed with a pile yarn of 100% wool on the surface of the primary base fabric, and an amorphous olefin polymer composition is formed on the back surface thereof to prevent the thread from coming off. Is applied to form a skin material with a liquid incombustible material attached to the pile surface,
The above backing material is coated with a paste of amorphous olefin polymer composition, and a plain woven mesh fabric composed of multifilament yarns of polyester fiber is overlaid, and this is heated to form an amorphous olefin polymer composition. The pasty material is melted, the above skin material is overlaid on it, and after pressurizing it, it is heated to stabilize the shape and dimensions. A method for producing a rugged gas generation rug comprising solidifying a paste-like body of a combined composition, bonding a backing material and a skin material, and cutting the material into a predetermined size.

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