JP6137748B2 - Flame retardant non-woven fabric - Google Patents
Flame retardant non-woven fabric Download PDFInfo
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- JP6137748B2 JP6137748B2 JP2013148641A JP2013148641A JP6137748B2 JP 6137748 B2 JP6137748 B2 JP 6137748B2 JP 2013148641 A JP2013148641 A JP 2013148641A JP 2013148641 A JP2013148641 A JP 2013148641A JP 6137748 B2 JP6137748 B2 JP 6137748B2
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- 239000004745 nonwoven fabric Substances 0.000 title claims description 89
- RNFJDJUURJAICM-UHFFFAOYSA-N 2,2,4,4,6,6-hexaphenoxy-1,3,5-triaza-2$l^{5},4$l^{5},6$l^{5}-triphosphacyclohexa-1,3,5-triene Chemical compound N=1P(OC=2C=CC=CC=2)(OC=2C=CC=CC=2)=NP(OC=2C=CC=CC=2)(OC=2C=CC=CC=2)=NP=1(OC=1C=CC=CC=1)OC1=CC=CC=C1 RNFJDJUURJAICM-UHFFFAOYSA-N 0.000 title claims description 56
- 239000003063 flame retardant Substances 0.000 title claims description 56
- 239000000835 fiber Substances 0.000 claims description 57
- 239000010410 layer Substances 0.000 claims description 46
- 238000000034 method Methods 0.000 claims description 17
- 239000002344 surface layer Substances 0.000 claims description 13
- 229920000728 polyester Polymers 0.000 claims description 12
- 239000011230 binding agent Substances 0.000 claims description 10
- 239000000806 elastomer Substances 0.000 claims description 10
- 229920001971 elastomer Polymers 0.000 claims description 9
- 229920002972 Acrylic fiber Polymers 0.000 claims description 7
- 230000002265 prevention Effects 0.000 claims description 6
- 239000000470 constituent Substances 0.000 claims description 4
- 238000003763 carbonization Methods 0.000 claims description 3
- 238000011056 performance test Methods 0.000 claims description 3
- 229920002994 synthetic fiber Polymers 0.000 claims description 3
- 239000012209 synthetic fiber Substances 0.000 claims description 3
- 238000010998 test method Methods 0.000 claims description 3
- 238000010438 heat treatment Methods 0.000 description 18
- 238000012360 testing method Methods 0.000 description 13
- 238000004519 manufacturing process Methods 0.000 description 7
- 239000000463 material Substances 0.000 description 6
- 230000000052 comparative effect Effects 0.000 description 5
- 238000002844 melting Methods 0.000 description 4
- 238000003825 pressing Methods 0.000 description 4
- 238000002485 combustion reaction Methods 0.000 description 3
- 230000006835 compression Effects 0.000 description 3
- 238000007906 compression Methods 0.000 description 3
- 239000004925 Acrylic resin Substances 0.000 description 2
- 229920000178 Acrylic resin Polymers 0.000 description 2
- 230000005484 gravity Effects 0.000 description 2
- 238000000691 measurement method Methods 0.000 description 2
- 230000008018 melting Effects 0.000 description 2
- 239000000203 mixture Substances 0.000 description 2
- 229910001220 stainless steel Inorganic materials 0.000 description 2
- 239000010935 stainless steel Substances 0.000 description 2
- OAICVXFJPJFONN-UHFFFAOYSA-N Phosphorus Chemical compound [P] OAICVXFJPJFONN-UHFFFAOYSA-N 0.000 description 1
- 239000004642 Polyimide Substances 0.000 description 1
- NIXOWILDQLNWCW-UHFFFAOYSA-N acrylic acid group Chemical group C(C=C)(=O)O NIXOWILDQLNWCW-UHFFFAOYSA-N 0.000 description 1
- 229920000800 acrylic rubber Polymers 0.000 description 1
- 239000000853 adhesive Substances 0.000 description 1
- 230000001070 adhesive effect Effects 0.000 description 1
- 238000007796 conventional method Methods 0.000 description 1
- 238000011549 displacement method Methods 0.000 description 1
- 239000010408 film Substances 0.000 description 1
- 238000010304 firing Methods 0.000 description 1
- 239000012943 hotmelt Substances 0.000 description 1
- 239000011810 insulating material Substances 0.000 description 1
- 239000000155 melt Substances 0.000 description 1
- 239000012528 membrane Substances 0.000 description 1
- 238000002156 mixing Methods 0.000 description 1
- 229910052698 phosphorus Inorganic materials 0.000 description 1
- 239000011574 phosphorus Substances 0.000 description 1
- 229920000058 polyacrylate Polymers 0.000 description 1
- 229920001721 polyimide Polymers 0.000 description 1
- 229920000642 polymer Polymers 0.000 description 1
- 238000012545 processing Methods 0.000 description 1
- 230000001105 regulatory effect Effects 0.000 description 1
- 230000003252 repetitive effect Effects 0.000 description 1
- 239000002759 woven fabric Substances 0.000 description 1
Landscapes
- Laminated Bodies (AREA)
- Nonwoven Fabrics (AREA)
Description
本発明は、表面を緻密化した難燃性不織布に関する。 The present invention relates to a flame retardant nonwoven fabric having a densified surface.
難燃性不織布は様々な分野に使用されており、マットや敷物類にも広く使用されている。例えば特許文献１にはリン含有高分子難燃剤で処理された不織布が提案されている。特許文献２にはアクリル系繊維を空気中で焼成した耐炎性繊維を含む不織布マットが提案されている。特許文献３にはポリイミド繊維を含む不織布、難燃マットが提案されている。 Flame retardant non-woven fabrics are used in various fields, and are widely used in mats and rugs. For example, Patent Document 1 proposes a nonwoven fabric treated with a phosphorus-containing polymer flame retardant. Patent Document 2 proposes a nonwoven fabric mat containing flame resistant fibers obtained by firing acrylic fibers in the air. Patent Document 3 proposes a nonwoven fabric and a flame retardant mat containing polyimide fibers.
しかし、前記従来の技術は、難燃性及びクッション性が乏しく、加工が難しかったり、製造コストが高いという問題があり、これらの改善が求められていた。 However, the conventional techniques have problems that flame retardancy and cushioning properties are poor, processing is difficult, and manufacturing costs are high, and these improvements have been demanded.
本発明は、前記従来の問題を解決するため、難燃性及びクッション性が高く、加工も容易で製造コストも安価な難燃性不織布を提供する。 In order to solve the above-mentioned conventional problems, the present invention provides a flame-retardant nonwoven fabric that has high flame retardancy and cushioning properties, is easy to process, and is inexpensive to manufacture.
本発明の難燃性不織布は、難燃性繊維とバインダー繊維を含む合成繊維製難燃性不織布であって、前記不織布の少なくとも一主面の表層は圧縮溶融固着された高密度層であり、前記難燃性繊維は難燃性ポリエステル繊維及び難燃性アクリル系繊維であり、前記バインダー繊維はエラストマー繊維であり、前記不織布の内層部の繊維密度は４０ｋｇ／ｍ 3 未満であり、前記表層の高密度層の繊維密度は４０ｋｇ／ｍ 3 以上であることを特徴とする。
Flame retardant nonwoven fabric of the present invention is a synthetic fiber made flame-retardant nonwoven fabric comprising the flame resistant fibers and the binder fibers, a surface layer of at least one main surface of the nonwoven fabric Ri dense layer der compressed melted and fixed The flame retardant fiber is a flame retardant polyester fiber and a flame retardant acrylic fiber, the binder fiber is an elastomer fiber, the fiber density of the inner layer portion of the nonwoven fabric is less than 40 kg / m 3 , and the surface layer The high-density layer has a fiber density of 40 kg / m 3 or more .
本発明は、不織布の少なくとも一主面の表層は圧縮溶融固着された高密度層であることにより、難燃性及びクッション性が高く、加工も容易で製造コストも安価な難燃性不織布を提供できる。すなわち、表面の高密度層は不織布を構成する表面部分の繊維が圧縮され溶融固着されているため、燃焼時には空気の供給を遮断し難燃性を高く維持できる。同様に表面の高密度層は薄皮が形成されている状態であり、上からの押圧力は周辺に分散することからクッション性も高い。また、表面の高密度層は剥離することもなく一体性が良好である。加えて、表面の高密度層は不織布を構成する表面部分の繊維が圧縮され溶融固着により形成できるため、加工も容易で製造コストも安価な難燃性不織布とすることができる。 The present invention provides a flame retardant nonwoven fabric having high flame retardancy and cushioning properties, easy to process and inexpensive to manufacture, because the surface layer of at least one main surface of the nonwoven fabric is a compression-melt-fixed high-density layer. it can. That is, in the high-density layer on the surface, the fibers of the surface portion constituting the nonwoven fabric are compressed and melt-fixed, so that the supply of air can be shut off during combustion and the flame retardancy can be maintained high. Similarly, the high-density layer on the surface is in a state where a thin skin is formed, and since the pressing force from above is dispersed in the periphery, the cushioning property is also high. Moreover, the high-density layer on the surface has good integrity without peeling off. In addition, the high-density layer on the surface can be formed by melting and fixing the fibers of the surface portion constituting the nonwoven fabric, so that it can be a flame-retardant nonwoven fabric that is easy to process and inexpensive to manufacture.
本発明者らは、難燃性繊維を含む合成繊維製難燃性不織布の表層を圧縮溶融固着して高密度層とすると難燃性が向上することを見出した。表面が緻密化すると、燃焼時に周囲から空気が供給されにくくなるからではないかと推測される。同様に、表面の高密度層は薄皮が形成されている状態であり、上からの押圧力は周辺に分散することから、クッション性も向上する。本発明においては、表裏面とも高密度層にすることもできるし、難燃性が必要とされる一面を高密度層にすることもできる。 The present inventors have found that flame retardancy is improved when the surface layer of a synthetic fiber flame-retardant nonwoven fabric containing flame-retardant fibers is compressed and fused to form a high-density layer. If the surface is densified, it is presumed that it is difficult to supply air from the surroundings during combustion. Similarly, the high-density layer on the surface is in a state where a thin skin is formed, and the pressing force from above is dispersed to the periphery, so that cushioning properties are also improved. In the present invention, both the front and back surfaces can be formed into a high-density layer, and one surface requiring flame retardancy can be formed into a high-density layer.
本発明の不織布の難燃性は、日本防災協会の寝具類における防炎製品性能試験基準、区分：ふとん類、試験法：４５°メセナミン法において、炭化長１０ｃｍ以下であることが好ましい。これは本発明の不織布は主としてふとん、座ぶとん、マットレス、ベッドパッド、枕、敷物、防災時などに使用する床マット等に適しているからである。もちろん前記以外の用途にも使用できる。 The flame retardancy of the nonwoven fabric of the present invention is preferably a carbonization length of 10 cm or less in the flameproof product performance test standards for bedding of the Japan Disaster Prevention Association, classification: futons, test method: 45 ° mesenamine method. This is because the nonwoven fabric of the present invention is mainly suitable for futons, sitting mats, mattresses, bed pads, pillows, rugs, floor mats used for disaster prevention and the like. Of course, it can be used for other purposes.
不織布の内層部の繊維密度は４０ｋｇ／ｍ3未満が好ましく、さらに好ましくは３０ｋｇ／ｍ3以下である。３０ｋｇ／ｍ3は一般的な比重の単位で示すと０．０３０ ｇ／ｃｍ3となり、かなり軽量であることを示す。そして、前記表層の高密度層の繊維密度は４０ｋｇ／ｍ3以上が好ましく、さらに好ましくは５０ｋｇ／ｍ3以上である。 The fiber density of the inner layer portion of the nonwoven fabric is preferably less than 40 kg / m 3 , more preferably 30 kg / m 3 or less. 30 kg / m 3 is 0.030 g / cm 3 in terms of a general specific gravity unit, which indicates that the weight is considerably light. And the fiber density of the high-density layer of the surface layer is preferably 40 kg / m 3 or more, more preferably 50 kg / m 3 or more.
不織布の全体厚みは１５ｍｍ以上が好ましく、さらに好ましい厚みは１５〜３０ｍｍである。表層の高密度層の厚みは４ｍｍ以下が好ましく、さらに好ましい厚みは２〜４ｍｍである。 The overall thickness of the nonwoven fabric is preferably 15 mm or more, and more preferably 15 to 30 mm. The thickness of the surface high-density layer is preferably 4 mm or less, and more preferably 2 to 4 mm.
難燃性繊維は難燃性ポリエステル繊維及び難燃性アクリル系繊維から選ばれる少なくとも一つであることが好ましい。これらの繊維は難燃性が高く、安価であり、加工もしやすいからである。難燃性ポリエステル繊維及び難燃性アクリル系繊維の混紡合割合は重量比で１００ :０〜０ :１００であり、任意の割合を選択できる。好ましくは８０ :２０〜２０ :８０の範囲である。 The flame retardant fiber is preferably at least one selected from a flame retardant polyester fiber and a flame retardant acrylic fiber. This is because these fibers have high flame retardancy, are inexpensive, and are easy to process. The blend ratio of the flame retardant polyester fiber and the flame retardant acrylic fiber is 100: 0 to 0: 100 in weight ratio, and any ratio can be selected. The range is preferably 80:20 to 20:80.
バインダー繊維は、ポリエステルエラストマー繊維を使用することが好ましい。ポリエステルエラストマー繊維は伸縮性及び接着繊維（ホットメルト繊維）として寄与する。とくに圧縮時に溶融固着して高密度層を形成する。加えて表面の滑り止め機能も発揮する。バインダー繊維の好ましい融点は１２０〜２５０℃であり、さらに好ましくは１５０〜２３０℃である。難燃性繊維とバインダー繊維の好ましい重量割合は、両者の合計を１００重量％としたとき、バインダー繊維の重量比は２０〜４０重量％である。 The binder fiber is preferably a polyester elastomer fiber. Polyester elastomer fibers contribute as stretch and adhesive fibers (hot melt fibers). In particular, it melts and fixes during compression to form a high-density layer. In addition, it has a non-slip function on the surface. The preferable melting point of the binder fiber is 120 to 250 ° C, more preferably 150 to 230 ° C. The preferred weight ratio of the flame retardant fiber and the binder fiber is such that the weight ratio of the binder fiber is 20 to 40% by weight when the total of both is 100% by weight.
不織布は、難燃性ポリエステル繊維と難燃性アクリル系繊維とエラストマー繊維と非難燃性ポリエステル繊維の混紡品であるのが好ましい。さらに好ましくは、難燃性ポリエステル繊維と難燃性アクリル系繊維とエラストマー繊維である。この混紡品であれば、密度及び重量が軽く、表面の圧縮溶融固着加工も効率よくできる。 The nonwoven fabric is preferably a blend of flame retardant polyester fiber, flame retardant acrylic fiber, elastomer fiber, and non-flame retardant polyester fiber. More preferred are flame retardant polyester fiber, flame retardant acrylic fiber and elastomer fiber. With this blended product, the density and weight are light, and the surface can be efficiently compressed and fused.
本発明の不織布は、クロスレイ不織布のように繊維が水平方向に配列していても良いが、好ましくは厚さ方向に構成繊維が配向しているのが好ましい。このような不織布は後の図２で説明する。 In the nonwoven fabric of the present invention, the fibers may be arranged in the horizontal direction as in the case of the cross-laid nonwoven fabric, but the constituent fibers are preferably oriented in the thickness direction. Such a nonwoven fabric will be described later with reference to FIG.
高密度層は不織布の表裏面に形成されていても良い。このようにすると、表裏面を上にするか下にするかどちらでも任意に使用できる。別の実施形態として、不織布の一主面の表層は圧縮溶融された高密度層であり、他の主面の表層には、多孔質で通気性を有する膜材料、フイルム、織物、不織布などのシート状の材料が好ましい。低コストの観点から、スパンボンド不織布がより好ましい。このようにすると防災などで使用する床マットの場合、高密度層を床面に向け、シート状の材料のほうを人体側に向けて配置できる。 The high density layer may be formed on the front and back surfaces of the nonwoven fabric. If it does in this way, it can be used arbitrarily regardless of whether the front and back are up or down. As another embodiment, the surface layer on one main surface of the nonwoven fabric is a high-density layer that is compressed and melted, and the surface layer on the other main surface is made of a porous and air-permeable membrane material, film, woven fabric, nonwoven fabric, etc. A sheet-like material is preferable. From the viewpoint of low cost, a spunbonded nonwoven fabric is more preferable. In this case, in the case of a floor mat used for disaster prevention or the like, the high density layer can be directed to the floor surface, and the sheet-like material can be arranged to face the human body.
以下、図面を用いて説明する。以下の図面において、同一符号は同一物を示す。図１Ａは本発明の一実施態様の難燃性不織布１の断面図、図１Ｂは同、別の実施態様の難燃性不織布の模式的断面図である。図１Ａは難燃性不織布１の内層２の表裏面に圧縮溶融固着された高密度層３ａ，３ｂを形成した例である。内層２の繊維は厚さ方向に配列した例を示している。高密度層３ａ，３ｂは内層２の繊維が連続的に圧縮溶融固着されている。図１Ｂの例は難燃性不織布５の内層２の一主面に高密度層３を設け、他の主面にはスパンボンド不織布層４を積層した例である。スパンボンド不織布層４は接着により積層できる。 Hereinafter, it demonstrates using drawing. In the following drawings, the same symbols indicate the same items. FIG. 1A is a cross-sectional view of a flame-retardant nonwoven fabric 1 according to one embodiment of the present invention, and FIG. 1B is a schematic cross-sectional view of a flame-retardant nonwoven fabric according to another embodiment. FIG. 1A is an example in which high-density layers 3 a and 3 b that are compression-melted and fixed to the front and back surfaces of the inner layer 2 of the flame-retardant nonwoven fabric 1 are formed. An example in which the fibers of the inner layer 2 are arranged in the thickness direction is shown. In the high density layers 3a and 3b, the fibers of the inner layer 2 are continuously compression-melted and fixed. The example of FIG. 1B is an example in which a high-density layer 3 is provided on one main surface of the inner layer 2 of the flame-retardant nonwoven fabric 5 and a spunbond nonwoven fabric layer 4 is laminated on the other main surface. The spunbond nonwoven fabric layer 4 can be laminated by adhesion.
図２は本発明の一実施態様の難燃性不織布の内層（基層）を製造する工程を示す模式的説明図である。まず難燃性繊維とバインダー繊維を含むカードウェブ６をベルトコンベア７によりガイドプレート８，９間に供給する。ガイドプレート８は傾斜面で構成され、カードウェブ６を下方に滑り落とす。ガイドプレート９は上下動しており、カードウェブ６を垂直方向に折り畳む。折り畳まれたカードウェブ６は水平プレート１１，１２間で熱セットされ不織布１３として成形され、右方向に押し出される。１０は不織布製造装置である。 FIG. 2 is a schematic explanatory view showing a process for producing the inner layer (base layer) of the flame-retardant nonwoven fabric of one embodiment of the present invention. First, a card web 6 containing flame retardant fibers and binder fibers is supplied between guide plates 8 and 9 by a belt conveyor 7. The guide plate 8 is composed of an inclined surface and slides the card web 6 downward. The guide plate 9 moves up and down and folds the card web 6 in the vertical direction. The folded card web 6 is heat-set between the horizontal plates 11 and 12, formed as a nonwoven fabric 13, and extruded rightward. Reference numeral 10 denotes a nonwoven fabric manufacturing apparatus.
図３は図２の製造工程で得られた圧縮溶融固着前の難燃性不織布の模式的断面図である。この不織布は、厚さ方向に構成繊維が配向しており、厚さ方向の圧縮弾性率が高くへたりにくい性質を有する。 FIG. 3 is a schematic cross-sectional view of the flame retardant nonwoven fabric before compression-melting and fixing obtained in the manufacturing process of FIG. This nonwoven fabric has the property that the constituent fibers are oriented in the thickness direction, and the compression elastic modulus in the thickness direction is high and is difficult to sag.
図４Ａは不織布１３の一主表面を圧縮溶融固着し、高密度層１５を形成する工程断面図である。カレンダーロール１６，１７間に不織布１３を通過させ、加熱ロール１６側の不織布面を圧縮溶融固着させる。これにより、高密度層１５が形成される。１４は内層である。加熱ロール１６の加熱温度は１８０〜２３０℃が好ましい。不織布１３がカレンダーロール１６，１７間を通過する速度は５〜３０ｍ／分が好ましい。 FIG. 4A is a process cross-sectional view in which one main surface of the nonwoven fabric 13 is compression-melted and fixed to form the high-density layer 15. The nonwoven fabric 13 is passed between the calendar rolls 16 and 17, and the nonwoven fabric surface on the heating roll 16 side is compression-melted and fixed. Thereby, the high-density layer 15 is formed. Reference numeral 14 denotes an inner layer. The heating temperature of the heating roll 16 is preferably 180 to 230 ° C. The speed at which the nonwoven fabric 13 passes between the calendar rolls 16 and 17 is preferably 5 to 30 m / min.
図４Ｂはガイドプレート１９と加熱プレート１８により、不織布１３の一主表面を圧縮溶融固着し、高密度層１５を形成する工程断面図である。加熱プレート１８の加熱温度は１５０〜２００℃が好ましい。不織布１３が加熱プレート１８を通過する速度は１〜１０ｍ／分が好ましい。 FIG. 4B is a process cross-sectional view in which one main surface of the nonwoven fabric 13 is compression-melted and fixed by the guide plate 19 and the heating plate 18 to form the high-density layer 15. The heating temperature of the heating plate 18 is preferably 150 to 200 ° C. The speed at which the nonwoven fabric 13 passes through the heating plate 18 is preferably 1 to 10 m / min.
図４Ｃは加熱ベルトコンベア２０と，ベルトコンベア２１により、不織布１３の一主表面を圧縮溶融固着し、高密度層１５を形成する工程断面図である。加熱ベルトコンベア２０の加熱温度は１５０〜２００℃が好ましい。不織布１３が加熱ベルトコンベア２０と，ベルトコンベア２１間を通過する速度は１〜１０ｍ／分が好ましい。 FIG. 4C is a process cross-sectional view in which one main surface of the nonwoven fabric 13 is compression-melted and fixed by the heating belt conveyor 20 and the belt conveyor 21 to form the high-density layer 15. The heating temperature of the heating belt conveyor 20 is preferably 150 to 200 ° C. The speed at which the nonwoven fabric 13 passes between the heating belt conveyor 20 and the belt conveyor 21 is preferably 1 to 10 m / min.
以下、実施例を用いてさらに具体的に説明する。なお、本発明は下記の実施例に限定されるものではない。 Hereinafter, more specific description will be made using examples. In addition, this invention is not limited to the following Example.
＜難燃性試験測定方法＞
難燃性は日本防災協会の寝具類における防炎製品性能試験基準、区分：ふとん類、試験法：４５°メセナミン法で測定する。図５は本発明の一実施形態の難燃性試験装置３０の模式的断面図であり、同測定方法を示している。水平面から４５°の角度にステンレス製プレート３１を配置し、ストッパー３２の上に不織布サンプル３３を置き、不織布サンプル３３の上にメセナミン３４を０．１５ｇ置き、これに火をつける。試験サンプル数５とし、難燃性は次の判断基準により判定する。判定は、炭化長：最大１０．０ｃｍ以下、平均８.０ｃｍ以下であれば合格、前記を超えると不合格とした。
<Flame retardance test measurement method>
Flame retardance is measured by the flame retardant product performance test standards for bedding of the Japan Disaster Prevention Association, Category: Futons, Test Method: 45 ° Mesenamine Method. FIG. 5 is a schematic cross-sectional view of the flame retardancy test apparatus 30 according to one embodiment of the present invention, and shows the measurement method. The stainless steel plate 31 is disposed at an angle of 45 ° from the horizontal plane, the non-woven fabric sample 33 is placed on the stopper 32, and 0.15 g of mesenamin 34 is placed on the non-woven fabric sample 33. The number of test samples is 5, and flame retardancy is determined according to the following criteria. The determination was carbonization length: a maximum of 10.0 cm or less and an average of 8.0 cm or less was acceptable, and if it exceeded the above, it was regarded as a failure.
＜繰り返し圧縮残留ひずみ＞
JIS K 6400-4 B法(定変位法)に従い、試験片全体を厚さの50%まで連続80000回繰返し圧縮することによって発生する厚さの低下率を求めた。計算式は次のとおりである。
Cfd＝（d1−d2）／d1×100
Cfd；厚さ低下率（％）
d1；初めの試験片厚さ（ｍｍ）
d2；試験後の試験片厚さ（ｍｍ）
<Repetitive compression residual strain>
According to the JIS K 6400-4 B method (constant displacement method), the reduction rate of the thickness generated by repeatedly compressing the entire test piece to 50% of the thickness continuously 80,000 times was determined. The calculation formula is as follows.
C fd = (d 1 −d 2 ) / d 1 × 100
C fd ; thickness reduction rate (%)
d 1 ; Initial specimen thickness (mm)
d 2 ; Test piece thickness after test (mm)
＜滑り止め性＞
図６に示す滑り止め測定装置４０を使用して測定した。この装置は、水平の状態のアクリル樹脂板４１の上に５０ｇの錘４３を乗せた２００ｍｍ×２５０ｍｍの試験試料４２を置き、アクリル実施板４１を徐々に傾けて、滑り出し角度Θを測定した。
<Non-slip property>
It measured using the anti-slip | skid measuring apparatus 40 shown in FIG. In this apparatus, a 200 mm × 250 mm test sample 42 on which a 50 g weight 43 was placed was placed on an acrylic resin plate 41 in a horizontal state, and the acrylic implementation plate 41 was gradually tilted to measure the sliding angle Θ.
（実施例１〜４、比較例１）
難燃性繊維として、東洋紡社製難燃ポリエステルFR,PET6.6dtex,51mmとカネカ社製、商品名“カネカロン”(LOI:33) 2.2dtex,51mmと、バインダー繊維として、帝人社製、商品名“エルク”（ポリエステルエラストマー）4dtex,64mmを表１に示す通りの繊維混率とし、カードウェブを製造し、実施例１〜４は図２に示す方法で不織布（Ａ）を製造した。断面図は図３に示すとおりである。図３に示す不織布１３の厚さは２５ｍｍであった。
(Examples 1-4, Comparative Example 1)
As flame retardant fibers, Toyobo's flame retardant polyester FR, PET6.6dtex, 51mm and Kaneka's product name "Kanekaron" (LOI: 33) 2.2dtex, 51mm, as binder fiber, Teijin's product name “Elk” (polyester elastomer) 4 dtex, 64 mm was used as a fiber mixing ratio as shown in Table 1 to produce a card web, and Examples 1 to 4 produced nonwoven fabrics (A) by the method shown in FIG. The cross-sectional view is as shown in FIG. The thickness of the nonwoven fabric 13 shown in FIG. 3 was 25 mm.
比較例１は、通常のクロスレアーでウエブを重ね合わせた後、厚みを２０ｍｍに規定しながら、温度が２００℃に設定された熱風サクション式熱処理機内に押し込み不織布（Ｂ）を製造した。 In Comparative Example 1, after the webs were overlapped with a normal cross layer, the nonwoven fabric (B) was manufactured by pressing into a hot air suction heat treatment machine set at a temperature of 200 ° C. while regulating the thickness to 20 mm.
実施例１〜２は不織布（Ａ）を、比較例１は不織布（Ｂ）を用いて、図４Ａに示す方法で一主面を圧縮溶融固着させた。熱ロール１６の温度は２００℃、通過する速度は１０ｍ／分であった。カレンダーロール１６，１７間の距離は実施例１では１８ｍｍ、実施例２では１９ｍｍとした。 In Examples 1 and 2, a nonwoven fabric (A) was used, and in Comparative Example 1, a nonwoven fabric (B) was used, and one main surface was compression-melted and fixed by the method shown in FIG. 4A. The temperature of the hot roll 16 was 200 ° C., and the passing speed was 10 m / min. The distance between the calendar rolls 16 and 17 was 18 mm in Example 1, and 19 mm in Example 2.
実施例３は、不織布（Ａ）を用いて、図４Ｂに示す方法で一主面を圧縮溶融固着させた。加熱プレート１８の温度は１８０℃、通過する速度は３ｍ／分であった。ガイドプレート１９と加熱プレート１８の間の距離は１９ｍｍとした。 In Example 3, one main surface was compression-melted and fixed using the nonwoven fabric (A) by the method shown in FIG. 4B. The temperature of the heating plate 18 was 180 ° C., and the passing speed was 3 m / min. The distance between the guide plate 19 and the heating plate 18 was 19 mm.
実施例４は、不織布（Ａ）を用いて、図４Ｃに示す方法で一主面を圧縮溶融固着させた。加熱ベルトコンベア２０ａの温度は１８０℃、通過する速度は３ｍ／分であった。加熱ベルトコンベア２０ａとベルトコンベア２０ｂの間の距離は１９ｍｍとした。 In Example 4, one main surface was compression-melted and fixed using the nonwoven fabric (A) by the method shown in FIG. 4C. The temperature of the heating belt conveyor 20a was 180 ° C., and the passing speed was 3 m / min. The distance between the heating belt conveyor 20a and the belt conveyor 20b was 19 mm.
得られた不織布の難燃性試験をした。図７Ａは実施例１の難燃性試験後の不織布の表面写真、図７Ｂは比較例１の不織布の表面写真である。図中黒くなっている部分が炭化した部分である。以上の条件と結果を表１にまとめて示す。 The obtained nonwoven fabric was tested for flame retardancy. 7A is a surface photograph of the nonwoven fabric after the flame retardancy test of Example 1, and FIG. 7B is a surface photograph of the nonwoven fabric of Comparative Example 1. In the figure, the blackened portion is the carbonized portion. The above conditions and results are summarized in Table 1.
以上の結果から次のことが分かった。
（１）実施例１〜２の難燃性不織布は、表層が圧縮溶融固着して高密度層となっており、燃焼時に周囲から空気が供給されにくくなると推測されるが、難燃性が向上した。
（２）実施例１〜２の難燃性不織布は、表層が圧縮溶融固着して高密度層となっていることから、滑り止め性も発現していた。
（３）同様に表面の高密度層は薄皮が形成されている状態であり、上からの押圧力は周辺に応力が分散することから、クッション性も高い。この性質は防災時などに使用する床マット、敷物、座ぶとん、マットレス、ベッドパッド、枕等に適している。
（４）実施例１〜２の難燃性不織布は、全体密度２６．３ｋｇ／ｍ3、一般的な比重の単位で示すと０．０２６３ｇ／ｃｍ3であり、空隙率は９７．３７％であり、かなり軽量である。これは運搬や日常の出し入れに負担がかからない利点を有している。
The following was found from the above results.
(1) The flame retardant nonwoven fabrics of Examples 1 and 2 have a high density layer with the surface layer being compression-melted and fixed, and it is estimated that air is less likely to be supplied from the surroundings during combustion, but the flame retardancy is improved. did.
(2) The flame retardant nonwoven fabrics of Examples 1 and 2 also exhibited anti-slip properties because the surface layer was compressed and fused and formed into a high-density layer.
(3) Similarly, the high-density layer on the surface is in a state where a thin skin is formed, and since the pressing force from above disperses stress around, the cushioning property is also high. This property is suitable for floor mats, rugs, sitting mats, mattresses, bed pads, pillows, etc. used for disaster prevention.
(4) The flame retardant nonwoven fabrics of Examples 1 and 2 have an overall density of 26.3 kg / m 3 , 0.0263 g / cm 3 when expressed in units of general specific gravity, and a porosity of 97.37%. Yes, it is quite lightweight. This has the advantage that there is no burden on transportation and daily taking in and out.
本発明の不織布は、床マット、敷物、座ぶとん、マットレス、ベッドパッド、枕等以外にも、緩衝材、断熱材、車両内装材、航空機内装材などにも適用可能である。 The nonwoven fabric of the present invention can be applied to cushioning materials, heat insulating materials, vehicle interior materials, aircraft interior materials, etc. in addition to floor mats, rugs, seat cushions, mattresses, bed pads, pillows and the like.
１，５ 難燃性不織布
２，１４ 内層
３，３ａ，３ｂ，１５ 高密度層
４ スパンボンド不織布層
６ カードウェブ
７ ベルトコンベア
８，９ ガイドプレート
１０ 不織布製造装置
１１，１２ 水平プレート
１３ 不織布
１６，１７ カレンダーロール
１８ 加熱プレート
１９ ガイドプレート
２０ 加熱ベルトコンベア
２１ ベルトコンベア
３０ 難燃性試験装置
３１ ステンレス製プレート
３２ ストッパー
３３ 不織布サンプル
３４ メセナミン
４０ 滑り止め測定装置
４１ アクリル樹脂板
４２ 試験試料
４３ 錘
1, 5 Flame retardant nonwoven fabric 2, 14 Inner layer 3, 3a, 3b, 15 High density layer 4 Spunbond nonwoven fabric layer 6 Card web 7 Belt conveyor 8, 9 Guide plate 10 Nonwoven fabric manufacturing apparatus 11, 12 Horizontal plate 13 Nonwoven fabric 16, 17 Calender roll 18 Heating plate 19 Guide plate 20 Heating belt conveyor 21 Belt conveyor 30 Flame retardant test device 31 Stainless steel plate 32 Stopper 33 Non-woven fabric sample 34 Mesenamine 40 Anti-slip measuring device 41 Acrylic resin plate 42 Test sample 43 Weight
Claims (5)
前記不織布の少なくとも一主面の表層は圧縮溶融固着された高密度層であり、
前記難燃性繊維は難燃性ポリエステル繊維及び難燃性アクリル系繊維であり、前記バインダー繊維はエラストマー繊維であり、
前記不織布の内層部の繊維密度は４０ｋｇ／ｍ 3 未満であり、前記表層の高密度層の繊維密度は４０ｋｇ／ｍ 3 以上であることを特徴とする難燃性不織布。 A flame retardant nonwoven fabric made of synthetic fiber containing flame retardant fibers and binder fibers,
Surface layer of at least one main surface of the nonwoven fabric Ri dense layer der compressed melted and fixed,
The flame retardant fiber is a flame retardant polyester fiber and a flame retardant acrylic fiber, the binder fiber is an elastomer fiber,
The flame retardant nonwoven fabric characterized in that the fiber density of the inner layer portion of the nonwoven fabric is less than 40 kg / m 3 , and the fiber density of the high density layer of the surface layer is 40 kg / m 3 or more .
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