JP4811739B2 - Flame retardant multi-woven fabric and fabric for vehicle interior - Google Patents

Description

  The present invention relates to a surface yarn constituting a surface of a woven or knitted fabric by being woven and knitted on the front and back of a woven or knitted fabric, such as a double face, a Milan rib, a three-port reversible, a double blister, and a double picket, which are mainly used as a vehicle interior fabric. The present invention relates to a multi-woven knitted fabric formed by connecting a back woven stitch of a back yarn constituting a front woven stitch and a back surface by a middle yarn.

  A vehicle interior fabric is required to have flame retardancy, and the flame retardancy is evaluated according to a test standard defined by the American automobile safety standard FMVSS 302 (see, for example, Patent Document 1). Flame retardant vehicle interior fabrics include a flame retardant polyester fiber (hereinafter simply referred to as “difficult”) having a limiting oxygen index LOI value (hereinafter simply referred to as LOI value) defined by JIS-K-7201 (B2 method) of 26 or more. (Referred to as Patent Document 2, 3, 4, 5).

The flame retardant polyester fiber includes a post-processed flame retardant polyester fiber (see, for example, Patent Document 3) obtained by adding a flame retardant to a general polyester fiber having a LOI value of less than 21 (hereinafter simply referred to as a general polyester fiber). There are kneaded flame retardant polyester fibers (see, for example, Patent Documents 2 and 4) in which a flame retardant is kneaded into a fiber polymer and spun.
As the flame retardant, Euler acid phosphate, isopropyl acid phosphate ester, phenylphosphonic acid, hexabromobenzene, polydiphenoxyphosphonitrile, tetrabromobisphenol A, tetrabromobisphenol S, triphenorphosphine oxide and the like are used ( For example, see Patent Document 2).

Japanese Patent Laid-Open No. 08-238708 Japanese Patent Laid-Open No. 51-55464 (Japanese Patent Publication No. 57-017991) JP 07-003658 A (Patent No. 3251388) JP 10-259542 A (Patent No. 3777707) Japanese Utility Model Publication No. 02-058930 (No. 06-05161)

  Flame retardant polyester fibers have problems in that they have less gloss than general polyester fibers, lack dyeability, and are expensive in cost.

  Accordingly, an object of the present invention is to obtain a multi-woven knitted fabric made of polyester fiber suitable for a vehicle interior fabric by reducing the amount of flame-retardant polyester fiber used and mixing it with general polyester fiber.

In a multi-woven fabric, flame retardancy is imparted by applying a flame retardant polyester fiber to the front yarn 11 and the back yarn 12 that are in direct contact with fire. Therefore, it was considered that the cost of the flame retardant multi-woven fabric can be reduced by using a general polyester fiber which is relatively inexpensive in terms of the middle yarn.
However, in order to reduce the cost of the flame-retardant multi-woven knitted fabric using such a flame-retardant polyester fiber, a flame-retardant multi-woven knitted fabric cannot be obtained when a general polyester fiber is used for the middle yarn 13.

The inventor considered the reason as follows. That is, since the front yarn 11 and the back yarn 12 constitute the woven stitches 14 and 15 and are intertwined, the fiber density is dense on the front and back of the multi-woven fabric. However, in the intermediate layer 23 between the front and back sides of the multi-woven fabric, the middle yarns 13 are individually forested in the thickness direction of the multi-woven fabric without forming a weave stitch, and the fiber density is coarse and porous. (See FIG. 1 and FIG. 2).
Therefore, the middle thread 13 of the intermediate layer 23 which is individually separated in a porous manner is the same as the bookbinding in which the paper is densely accumulated is harder to burn than the piled paper waste which is crumpled and has many internal voids. Is more easily melted and decomposed and combusted than the front and back yarns 11 and 12 of the multi-woven knitted fabric that is intertwined and in a dense state.
And if the middle thread 13 melts and breaks, the outer material 21 and the lining 22 released and separated from the middle thread 13 become more easily combustible so that the wrinkles are finely broken and easily burned.

Actually, for example, aluminum hydroxide or magnesium hydroxide used as a flame retardant, when finely crushed and applied to fibers or plastics, it generates water vapor in contact with the flame and exhibits a flame retardant effect due to endothermic action, etc. However, granular aluminum hydroxide or magnesium hydroxide, not fine powder, does not exhibit a particularly flame-retardant effect.
Then, when considering that it is easy to burn if the cocoon is broken finely, it is not the front yarn 11 and the back yarn 12 in which the fiber density is dense, but the medium yarn 13 in which the fiber density is coarse and easy to touch the air. It was considered that the flame retardant polyester fiber exerted the flame retardant effect only when the flame retardant polyester fiber was used.

  Thus, the present inventor reduced the amount of flame retardant polyester fiber used for the front and back yarns that would directly come into contact with fire in the event of a fire without reducing the amount of flame retardant polyester used for the middle yarn. As a result, the inventors have obtained the knowledge that the cost reduction of the flame retardant multi-woven knitted fabric using the flame retardant polyester can be achieved without impairing the flame retardant performance, and the present invention has been completed.

  The multiple woven knitted fabric according to the present invention comprises: (a) a front woven stitch of a front yarn constituting the surface of the knitted knitted fabric by being woven and knitted on the front and back of the woven knitted fabric; In the multi-woven knitted fabric connected by the middle yarn, (b) the front yarn, the back yarn and the middle yarn are made of polyester fiber, and (c) the flame retardant having a limiting oxygen index LOI value of 26 or more is given to the middle yarn. And (d) the mass of the flame retardant middle yarn constituting the flame retardant polyester fiber in the total mass of the multi-woven fabric is 15% by weight or more, and (e) the front yarn and the back The first feature is that a combustible general polyester fiber having a limiting oxygen index LOI value of 21 or less is used for at least one of the yarns.

A second feature of the multi-woven fabric according to the present invention is that, in addition to the first feature, (f) the single fiber fineness of each of the front yarn, the back yarn and the middle yarn is 8 dtex or less, and the total fineness is 80 (G) The total mass of the multi-woven fabric is 250 to 800 g / m ² , and the mass of the flame-retardant polyester fiber in the total mass of the multi-woven fabric is 15 to 60% by weight. is there.

  A third feature of the multi-woven fabric according to the present invention is that, in addition to any of the first and second features, the multi-woven fabric is a multi-weft fabric, and the air permeability of the multi-woven fabric Is 50 to 180 cc / sec, preferably 70 to 160 cc / sec.

  A vehicle interior fabric according to the present invention is characterized by being composed of a flame-retardant multi-woven knitted fabric having any one of the first, second and third characteristics.

  In the present invention, as a result of using the flame retardant polyester fiber in the middle yarn, it is possible to effectively impart flame retardancy to the multi-woven fabric with the small amount of use, and because the amount of use is small. Further, it is possible to avoid a decrease in gloss and color of a multi-woven knitted fabric due to the flame-retardant polyester fiber and an increase in cost.

In the present invention, as long as the required flame retardance is ensured, general polyester fibers can be mixed in the middle yarn 13, and the appearance quality such as gloss and color tone of the multi-woven knitted fabric, the tensile strength, and the resistance to resistance. As long as the physical properties such as wear are not impaired, flame retardant polyester fiber can be mixed with the front yarn 11 and the back yarn 12.
That is, in a weft knitting structure in which a plurality of types (plural) of front yarns 11, back yarns 12 or intermediate yarns 13 are separately fed from different yarn feeders into each course and knitted, any of the plural types (plural) Flame retardant polyester fiber can be used for the front yarn, back yarn or middle yarn, and general polyester fiber can be used for any other front yarn, back yarn or middle yarn.

However, as shown in Examples 3 and 9 described later, a preferred embodiment of the present invention is that the front yarn 11 and the back yarn 12 do not use flame retardant polyester fiber, but use only general polyester fiber. is there.
In that case, when using a multi-woven fabric, only a general polyester fiber is used for the front yarn on the front side.
Thus, when using only a general polyester fiber for the front yarn 11 and the back yarn 12, the flame retardant polyester fiber whose LOI value is 24 or more, preferably 26 or more is used for the middle yarn.

Moreover, the preferable embodiment of this invention is not only using a flame-retardant polyester fiber for the middle thread 13, but applying the general thread | yarn which consists of a general polyester fiber.
Specifically, in a weft knitting structure in which a plurality of types (multiples) of yarns are fed separately from different yarn feeders and knitted as intermediate yarns, any one of the multiple types (multiples) of yarns Increase the LOI value of (medium thread).
For example, when a flame-retardant polyester fiber having a LOI value of 28 or more is used for any yarn (medium yarn), the LOI value is 21 or less for any other yarn (medium yarn). Use polyester fiber.

As described above, according to the present invention, the front and back yarns 11 and 12 of the multi-woven knitted fabric in which the intermediate yarns 13 of the intermediate layer 23 that are individually separated in a porous form are intertwined and intertwined into a dense state. It is based on the knowledge that it is easily melted and decomposed and combusted as compared to the above, the middle thread 13 is melted and broken, and the outer surface 21 and the lining 22 are separated and easily burned.
Therefore, in order to prevent the middle yarn 13 from being melted and broken between the outer material 21 and the inner material 22 and difficult to separate into the outer material 21 and the inner material 22, the number of intermediate yarns 13 interposed between the outer material 21 and the inner material 22 is extremely small. The outer surface 21 and the lining 22 are tightly integrated with each other through the middle thread 13 so that the middle thread 13 is not easily exposed to the flame and hardly melts and breaks between the outer surface 21 and the lining 22.

Therefore, in a preferred embodiment of the present invention, the total thickness of the thickness of the outer material 21 and the inner material 22 occupying 70% or more of the total thickness of the multi-woven fabric, and the intermediate yarn 13 interposed between the outer material 21 and the inner material 22. The ratio of the intermediate layer 23 to the total thickness of the multi-woven fabric is 30% or less, preferably 20% or less, more preferably 10% or less, and the outer material 21 and the lining material 22 are closely integrated.
That is, FIGS. 1 and 2 illustrate the woven / knitted structure of a multi-woven knitted fabric. In FIGS. 1 and 2, the thickness of the intermediate layer 23 shown in FIG. 21 and the lining 22 are closely attached.

  According to the present invention, by reducing the amount of flame retardant polyester fiber used, the cost of the flame retardant multi-woven fabric can be reduced, and the appearance quality such as touch and texture, gloss and color tone, tensile strength and expansion and contraction can be reduced. In terms of physical properties such as properties, a flame-retardant multi-woven fabric that is equivalent to a non-fire-retardant general multi-woven fabric (for example, Comparative Example 1 described later) that does not use a flame-retardant polyester fiber can be obtained.

  In order to prevent the middle yarn 13 from being melted and fractured between the outer material 21 and the inner material 22 and difficult to separate into the outer material 21 and the inner material 22, at least the outer weaving stitch 14 of the outer material 21 and the inner weaving fabric 15 of the inner material 22 are at least The four pieces are connected by the middle thread 13 at a rate of one piece, and the outer material 21 and the lining material 22 are intimately integrated.

In the present invention, the single fiber fineness of each of the front yarn, the back yarn and the middle yarn is 8 dtex or less, the total fineness is 80 to 650 dtex, and the total mass of the multi-woven fabric is 250 to 800 g / m ^2. This is to obtain a flame retardant multi-woven fabric suitable for a vehicle interior fabric in terms of quality and physical properties.
In a flame-retardant multiple weft knitted fabric, the stitch density calculated as the product of the wale density and the course density is generally 400-1500 pieces / (25.4 mm) ² and the air permeability is 50-180 cc / sec, preferably 70 to 160 cc / sec.

FIG. 1 shows a multiple weft knitted fabric having a double face weft knitted structure, and FIG. 2 shows a multiple weft knitted fabric having a Milan rib weft knitted structure.
As shown in FIG. 1 and FIG. 2, in the present invention, “multiple knitted fabric” means that the front yarn 11 and the back yarn 12 are separately woven and knitted into a front material 21 and a back material 22, respectively. It means a woven or knitted fabric in which an intermediate layer 23 of the middle thread 13 is interposed between the linings 22. Accordingly, in the “multiple knitted fabric” referred to in the present invention, as shown in the Milan rib weft knitted structure of FIG. 2, the needle loop 16 of the middle yarn 13 constitutes a part of the stitches of the outer fabric 21 and the lining 22. It may be a thing.
1 and FIG. 2 do not show an actual image of the multiple weft knitted fabric faithfully enlarged, as described above, and the intermediate layer 23 of the middle thread 13 is interposed between the outer fabric 21 and the lining 22. In this case, the outer fabric 21 and the lining 22 may be bound together via a middle thread 13 and closely integrated.

  In order to knit a multiple weft knitted fabric in such a manner, a weft knitting machine in which a front thread needle and a back thread needle are separately mounted, that is, a two-row needle bed flat knitting machine, a dial needle, A circular knitting machine equipped with a cylinder needle is used.

General polyester fiber multifilament yarn A-1 having a single fiber fineness of 1.2 dtex and a total fineness of 330 dtex, general polyester fiber multifilament yarn A-2 having a single fiber fineness of 4.7 dtex and a total fineness of 167 dtex, and a single fiber fineness of 4.7 dtex General polyester fiber multifilament yarn A-3 having a total fineness of 330 dtex, general polyester fiber multifilament yarn A-4 having a single fiber fineness of 3.5 dtex and a total fineness of 167 dtex, single fiber fineness of 1.2 dtex, total fineness of 330 dtex, LOI Post-processed flame-retardant polyester fiber multifilament yarn B having a value of 26, kneaded flame-retardant polyester fiber multifilament yarn C-1 having a single fiber fineness of 3.5 dtex, a total fineness of 330 dtex, and a LOI value of 29, and a single fiber fineness of 3 .5 dtex, total fineness 167 tex, kneaded flame retardant polyester fiber multifilament yarn C-2 with a LOI value of 29 is used separately for front yarn, back yarn and middle yarn, wale density 30 wale / 25.4 mm, course density 25 course / 25.4 mm, 11 types of multi-weft knitted fabrics with a stitch density of 750 pieces / (25.4 mm) ² and a total mass (weight) of 410 g / m ² were knitted and tested for flame retardancy according to the American automobile safety standard FMVSS 302 [Table 1 The results shown in FIG.

In [Table 1], the flame retardancy is measured by measuring the distance that the fire of the test piece that has been ignited by touching the fire source travels in 1 minute as the combustion speed, and the travel distance is displayed in units of "mm". .
In the flame retardant performance data shown in [Table 1], “0” indicates that the flaming point of the test piece was melted, the melt dripped down, and the flame did not move, and “−” Indicates that the test piece did not reach flame.

  In the present invention, the “LOI value” means the minimum oxygen concentration required for a substance to maintain flammability in a mixed gas atmosphere of oxygen and nitrogen. The higher the LOI value, the more the flame retardancy performance. Means high.

It is a perspective view which shows the knitting structure of a multiple weft knitted fabric. It is a perspective view which shows the knitting structure of a multiple weft knitted fabric.

Explanation of symbols

11: Front yarn 12: Back yarn 13: Middle yarn 14: Woven stitch 15: Woven stitch 16: Needle loop 21: Outer fabric 22: Lining 23: Intermediate layer

Claims (4)

(A) Multi-woven knitting in which front and back stitches of the front yarn constituting the surface of the knitted knitted fabric are woven and knitted on the front and back sides of the knitted knitted fabric and the back woven stitches of the back yarn constituting the back are connected by the middle yarn In the ground
(B) The front yarn, the back yarn and the middle yarn are made of polyester fiber,
(C) A flame retardant polyester fiber having flame retardancy having a limiting oxygen index LOI value of 26 or more is used for the middle thread,
(D) The mass of the flame retardant middle yarn comprising the flame retardant polyester fiber in the total mass of the multi-woven fabric is 15% by weight or more,
(E) A flame retardant multiwoven knitted fabric in which flammable general polyester fibers having a limiting oxygen index LOI value of 21 or less are used for at least one of the front yarn and the back yarn. (F) The single yarn fineness of each of the front yarn, the back yarn and the middle yarn is 8 dtex or less, and the total fineness is 80 to 650 dtex,
(G) The total mass of the multi-woven fabric is 250 to 800 g / m ² , and the mass of the flame-retardant polyester fiber in the total mass of the multi-woven fabric is 15 to 60% by weight. Flame retardant multi-woven knitted fabric.   The flame-retardant multi-woven fabric according to any one of claims 1 and 2, wherein the multi-woven fabric is a multi-weft knitted fabric and has an air permeability of 50 to 180 cc / sec.   A vehicle interior fabric constituted by the flame retardant multi-woven fabric according to any one of claims 1, 2 and 3.

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