JPH059864A - Flame retardant fabric - Google Patents

Abstract

PURPOSE:To obtain a flame retardant fabric, excellent in handleability such as cutting and having a high tensile strength without emitting toxic gases by fusing a specific amount of heat bonding fiber to a polyester fiber fabric containing a specified amount of phosphorus element. CONSTITUTION:Heat bonding fiber (preferably polyester-based or nylon-based heat bonding fiber) in an amount of <=40wt.%, preferably 3-25wt.% based on a flame retardant polyester fabric containing 3000-10000ppm, preferably 4000-7000ppm phosphorus element is mixed in at least one direction of the polyester fiber fabric, thermally melted and bonded to the polyester fiber. Thereby, the objective flame retardant fabric, good in handleability and having a high tensile strength and excellent flame retardancy is obtained. The heat bonding fiber is preferably mixed with the polyester fiber by mix spinning, combining, plying, covering, etc., and used.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a flame-retardant fabric suitable for use in furniture, chairs of vehicles, interior interior parts such as roll curtains, and more particularly, it has high strength and heat resistance. The present invention relates to a highly flame-retardant fabric having appropriate hardness for improving the handling workability during cutting and sewing and in which misalignment of seams does not easily occur.

[0002]

2. Description of the Related Art Conventionally, as auxiliary fabrics for passenger seats such as railroad cars, automobile cars, ships, etc., seats for hotels, theaters, households, etc., natural fibers such as cotton, hemp, rayon, etc. Woven / knitted fabrics made of synthetic fibers such as fibers, vinylon, polyester / rayon and the mixed fibers, warp knitted fabrics made of nylon / polyester filaments, and various fabrics such as spunbond and non-woven fabric made of nylon and polyester are used. Has been. The auxiliary cloth referred to here is
A cloth used to assist cushioning materials (urethane foam, etc.) commonly called lining cloth (skin cloth) and a seat structure skeleton part called hanging cloth (hanging cloth) and a seat skin (chair upholstery or surface cloth) Generally, it refers to various auxiliary fabrics (reinforcement) other than the outer skin, such as a fabric mainly used for bonding and a fabric used for a stile (skirt portion) or a clevis portion.
By the way, auxiliary fabrics have various required characteristics such as strength, heat resistance, sewability, and handleability, but in recent years, the demand for flame retardancy has been increasing from the standpoint of humanitarian safety. .. Especially for railways, subways, and aircraft interior materials (seat cushions, carpets, etc.), which are public transportation means, the Ministry of Transport Civil Aviation Bureau Notification (TCL1008-691969.3.
7), and railway vehicle interior materials (Rule No. 81 with 1969.5). Furthermore, in recent years, the range of regulations for flame retardancy has been expanding rapidly due to increasing social needs, and administrative guidance on flame retardancy for upholstered furniture such as theaters and hotels (Director of the Fire and Disaster Management Agency, Emergency Prevention Section) No. 129 (1986.9)) and instructions from the Ministry of International Trade and Industry regarding domestic flame retardancy of automobile interior materials (currently being implemented for exported vehicles). In response to these regulations of flame retarding seats, administrative guidance, and voluntary regulations in the industry, there are the following two conventional methods for flame retarding auxiliary seat fabrics. One is to use flammable cloth such as cotton, fabric, synthetic fiber, etc. on a phosphorus-containing flame retardant (for example, water-soluble aminoplast phosphate, phosphorus-containing organic substance) or halogen-containing flame retardant (for example, halogen-containing organic substance,
Halogen-containing polymers), sulfur-containing flame retardants (eg, sulfur-containing compounds, thiourea compounds, etc.) or inorganic flame-retardants (eg, ammonia salts, inorganic acids, alkali metal salts, metal compounds, etc.)
Exhausted by itself or in combination, or fixed with water-soluble hard finish resin (acrylic thread, vinyl acetate, urethane, melamine, urea, vinyl chloride, etc.) by pad dry cure Another method is to make the flame-retardant by post-processing, and the other is to obtain a flame-retardant cloth using a flame-retardant material in which the fibers themselves are self-extinguishing.

[0003]

However, these methods have the following drawbacks. That is, the former method, depending on the type of each fabric, causes a decrease in strength over time (embrittlement) due to improper quality or amount of the flameproofing agent or variation.
Odor generation, in the case of inorganic flame retardant, white powder generated due to crystal precipitation due to moisture absorption / release, rust phenomenon on seat components due to hygroscopic disaster-prevention agent, and variation / decrease in flame retardant performance depending on processing lot There were various drawbacks, and there was a need for improvement. On the other hand, as the latter method, various known flame-retardant materials such as polyclar, flame-retardant acrylic, acrylic,
A cloth using a heat-resistant flame-retardant material such as polyvinyl chloride, flame-retardant polyester, aramid, and novoloid is conceivable. However, a cloth made of polyclar has been mainly used for the following reasons. That is, as described above, the seat auxiliary fabric has high strength as required properties other than flame retardant performance, high heat resistance, workability during cutting and sewing, and appropriate hardness to improve handleability. In addition, there is little seam shift, it is cheap, and more recently, from the viewpoint of human life and environmental hygiene, poisonous gas (for example, hydrogen cyanide, hydrogen chloride, etc.) at the time of combustion is required. It is strongly desired that the occurrence is as low as possible. In order to meet the above required characteristics, a cloth made of acrylic, flame-retardant acrylic, polyvinyl chloride or the like has a LOI value of 28 to
It has a high strength of 37, high flame retardancy but low strength, particularly low heat resistance, and has the drawback that the shrinkage of the fabric is large due to heat treatment such as wrinkle stretching after seat seat sewing, and further, hydrogen cyanide during combustion. It has the drawback of generating hydrogen chloride gas and is not used. Further, heat-resistant fibers such as aramid and novoloid are not used because they have high strength, high heat resistance and flame retardance, but they are expensive and cannot be dyed. Next is flame-retardant polyester, but its strength is also greater than that of acrylic, flame-retardant acrylic, polyvinyl chloride-based materials, etc.
There is no problem with heat resistance and it is a suitable material. However,
Since the flame-retardant mechanism is mainly a method of moving away from the flame by melting (melt-away), various types of water-soluble resin treatment for preventing the above-mentioned moderate hardness required for the seat fabric and seam deviation However, it has a drawback that the flame retardancy is significantly reduced. Various water-soluble resins include, for example, starch, PVA, acrylics, melamines, ureas, vinyl chlorides, etc., but these interfere with the mechanism of moving away from the flame due to melting of the flame-retardant polyester, or become a charcoal so-called candle core. It reduces the flame retardancy by playing the role of. Furthermore, although it is polyclar, since it uses a vinyl chloride component as a flame-retardant component, it has a high degree of flame-retardancy and less deterioration of flame-retardant properties due to various water-soluble resins, and it has been mainly used in the conventional fabrics. There is a drawback that hydrogen chloride gas is sometimes generated, and further improvement is required in terms of strength and heat resistance. The present invention has the above-mentioned drawbacks of the conventional flame-retardant cloth, that is, strength reduction (embrittlement) with time, generation of odor, generation of white powder,
Rust phenomenon to seat components, variations in flame retardancy, etc.
An object of the present invention is to solve the drawbacks of the flame-retardant material in which toxic gases such as hydrogen cyanide and hydrogen chloride gas are generated during combustion and to provide a hard flame-retardant cloth.

[0004]

The present invention adopts the following means in order to solve the above problems. That is, the present invention uses at least 3,000 ppm of phosphorus element as a flame retardant component.
It is a flame-retardant fabric characterized in that, in a polyester fiber fabric containing ˜10,000 ppm, 40% by weight or less of the heat-bonding fiber is mixed and fused to the fabric.

The present invention will be described in detail below. In the present invention, the polyester fiber contains the phosphorus element of 3000 to 1
Must contain 0000 ppm. The elemental phosphorus is necessary for imparting a high degree of flame retardance, and even if a compound containing the elemental phosphorus is mixed or copolymerized at the raw material stage, or treated at a yarn stage or a fabric stage using a dyeing processing facility or the like. May be. In order to make the polyester fiber flame-retardant, a halogen element (bromine or the like) flame retardant is used in addition to the phosphorus element, but it is preferable to use the phosphorus element as the main component from the viewpoint of generating a toxic gas during combustion. 3000ppm of phosphorus element
If it is less than the above range, the flame retardance is lowered, which is not preferable. On the other hand, if it exceeds 10,000 ppm, the original physical properties of the fiber deteriorate, which is not preferable. Preferably 4000-700
0ppm is good. In addition, in the cloth made of the polyester fiber, it is preferable that at least 40% by weight or less of the heat-bonding fiber is mixed with the cloth in at least one direction of the cloth. Polyester fiber is selected because it is excellent in strength among general fibers, but the use of heat-bonded fiber is particularly important in the present invention. The fabric of the present invention is required to have appropriate hardness and a small seam deviation,
It is important not to reduce the flame retardancy of the polyester fiber, the method using the water-soluble resin described above, for example, melamine-based resin has the effect of increasing the hardness in a small amount, but significantly reduces the flame retardancy, Even if a large amount of starch is used, the flame retardancy does not easily decrease, but the resin film strength is low, so the adhesive strength is weak and there is no effect of preventing seam misalignment. It has been difficult to satisfy both the requirements for obtaining and for not reducing flame retardancy. In addition, it is preferable to mix them in one direction in order to improve fabricability such as weaving property and knitting property.

Further effects can be obtained by using the heat-bonding fiber, and further by uniformly blending the polyester fiber with the polyester fiber by a method such as blending, blending, twisting, and covering. Compared with the method using resin processing, it is possible to suppress components other than polyester fibers as much as possible, and it is possible to obtain a fabric with appropriate hardness that prevents misalignment of the fabric without reducing flame retardancy. That is, it acts as an adhesive effect directly on the points of contact between the yarns of the fabric structure, and by itself fusing, it produces an appropriate hardness. As the heat-bonding fiber, in principle, any heat-bonding fiber may be used as long as it has good adhesiveness to the polyester fiber. For example, a single polymer with a low melting point type (nylon, etc.), a different polymer core-sheath or side-by-side type (polyethylene / polypropylene, etc.), a different polymer core-sheath or side-by-side type (low melting point polyester / normal polyester, etc.) Things are available. In the present invention, it is preferable to use a polyester-based heat-bonding fiber whose thermal properties and decomposition / combustion process are similar to each other as much as possible in view of flame retardancy, and a polyester-based heat-bonding fiber or a nylon-based heat-bonding fiber. Adhesive fibers are particularly preferred. Further, from the viewpoint of the strength of the fabric, the prevention of seam shift and the adhesion efficiency, the heat-bonded fiber is structurally different from the melt type of a single polymer in that the core sheath or the side-by-side of a different polymer or the same kind of different polymer is used. preferable.

Here, it is an important point that the thermal bonding fiber is mixed in an amount of 40% by weight or less with respect to the polyester fiber cloth. When it exceeds 40% by weight, the flame retardancy of the cloth is lowered and the cloth of the present invention cannot be obtained. It is preferably 2 to 40% by weight, more preferably 3 to 25% by weight. If the amount of the heat-bonding fiber is less than 2% by weight, the fabric cannot exhibit appropriate hardness and the effect of preventing seam deviation. Further, the heat-bonding fiber is mixed in at least one direction of the cloth, but preferably, it is partially coordinated when it is mixed and integrated with the polyester fiber (for example, mixed spinning, mixed fiber, ply twist, covering, etc.). Therefore, it is suitable for improving the hardness, preventing the seam shift, and maintaining and stabilizing the flame retardancy. It is important for the cloth to completely melt the heat-adhesive fibers by heat treatment so as to adhere to the polyester fibers, and it is necessary to treat the cloth at a temperature higher than the melting point of the heat-adhesive fibers.
The heat medium may be hot air, moist heat steam, heated hot water, far infrared rays, or the like.

[0008]

[Examples] Examples 1 to 4, Comparative Examples 1 to 3, and Conventional Example 1 Polyester fibers containing 2500 and 35 phosphorus elements, respectively.
2d × 51 mm raw cotton containing 00, 5000, 60,000 and 7,000 ppm and 100d-48f filament containing 6000 ppm of phosphorus element were used. As a heat-bonding fiber, polyester core / sheath type (core-sheath area ratio 50/50%, core-sheath polymer melting point 265 ° C / 135 ° C)
A fabric was manufactured under the conditions shown in Table 1 by using a raw material 3d × 51 mm and a nylon-based polymer filament having a melting point of 110 ° C. of 70d-10f, and the characteristics were measured.

[0009]

[Table 1]

[0010]

[Table 2]

In Examples 1 and 2, 3 elements of phosphorus were added to each warp.
The polyester raw cotton 10 containing 500 and 5000 ppm
20s / 1 spun yarn consisting of 0% is mixed with the same raw cotton as the weft yarn and the polyester-based core / sheath type heat-adhesive fiber in a mixing ratio of 9
A plain woven fabric was woven using 4/6 and 90/10 20s / 1 mixed yarns. The mixing ratio of the heat-bonding fibers in the obtained cloth was 3% by weight and 5% by weight, respectively, with respect to the entire cloth. The obtained cloth was heat-treated at 200 ° C. for 1 minute using a tenter to obtain a hard cloth. The obtained cloth has an appropriate cloth hardness suitable for handling workability such as cutting and sewing, and has no cloth mottle on the cut surface. Polyclaar / polyester 70/3 of the conventional example
The performance was almost the same as that of the standard fabric composed of 0% blended yarn 20s / 1. Furthermore, the tensile strength of the fabric is greatly improved compared to the conventional example, particularly heat resistance, shrinkability in high temperature atmosphere),
Regarding the generation of toxic gas during combustion, it showed a high level of performance that cannot be obtained with the conventional fabric, and also showed good results in various flame retardancy tests. In Example 3, phosphorus element 6000
ppm polyester filament yarn 100d-24f
When using the Tricot 22G 2 sheet full set guide bar to knit a Quinn's code structure, 3 × 1 wrap,
Nylon-based heat-bonding fibers 70d-10f were arranged and knitted in this gap to obtain a cloth, which was heat-treated at 180 ° C. for 1 minute to obtain a hard cloth. Example 4 has a phosphorus element of 7,000 ppm.
A 65/35 blended yarn 10s / 1 of the contained polyester fiber and the polyester-sheath type fiber is spun to obtain a plain woven fabric,
Heat treatment was performed at 200 ° C. for 1 minute to obtain a hard cloth. In Examples 3 and 4, fabrics having improved hardness and further excellent cloth frayability were obtained in Examples 3 and 4, and further, heat resistance of the fabrics, generation of toxic gas during combustion, and flame retardancy. A fabric having unprecedented characteristics was obtained, which had no problem even in. Comparative Example 1 has a blending ratio of 55 with a polyester containing 7000 ppm of phosphorus and a polyester-based core-sheath fiber.
A plain woven fabric composed of a mixed yarn of 4/45 20s / 1 was heat treated at 200 ° C. for 1 minute in the same manner to obtain a hard cloth. Although the hardness and cloth frayability of the cloth are extremely good, Since the mixing ratio of the adhesive fibers was 45% by weight with respect to the entire fabric, the flame retardancy was insufficient. In Comparative Example 2, 20 s / 1 obtained by mixing 6% by weight of the heat-adhesive fiber only in the weft of the woven fabric was used, and the proportion of the heat-adhesive fiber used in the entire fabric was 3% by weight, and the phosphorus element content of the polyester fiber was 2500 ppm. Therefore, the flame retardancy was poor. In Comparative Example 3, phosphorus element 6000 pp
20s spun yarn consisting of 100% m-containing polyester fiber
After weaving a plain woven fabric using / 1 as the background, PVA 6%
After dipping in the solution-squeezing with a nip roller (pickup rate 100%), followed by heat treatment at 200 ° C. for 1 minute to obtain a hard cloth. The obtained fabric had no problem with respect to hardness and frayability of the fabric at all, but flame retardancy was impaired by the resin because it was a phosphorous element-containing fabric, and both tests failed. It was

Incidentally, Examples 1, 2, 4 and Comparative Examples 1, 2,
No. 4, water-soluble polyester emulsion / PV4 / oil agent = (70/20/10)
% Solid content ratio 6% was applied and weaving was performed. In the table, W indicates weft and T indicates warp. Moreover, the measuring method in the table was based on the following method. Fabric hardness JIS L1079 45 ° cantilever method Misalignment resistance JIS L1096 6.16.2
Method A (thread drawing method) Tensile strength of cloth JIS L1096 Labeled strip method Shrinkage of cloth (I) JIS L1042 Method D (II) Dry heat 200 ° C x 2 minutes Flame resistance / vehicle material test: For JRS railway vehicles Material flammability standard. According to the categories of non-combustion, extreme flame retardancy, and flame retardancy, the flame retardancy rank or higher was passed. -FMVSS302: A combustion test method for automobile interior materials. Those with a burning rate of 4 inches / minute or less were accepted. -Firefighting method (45 ° tension method): 45 ° micro burner method. The carbonized area was 30 or less, the afterflame time was 3 seconds or less, and the dust removal time was 5 seconds or less. Toxic gas during combustion JIS K7217 Air temperature 750 ° C Air amount 500ml / min

[0013]

INDUSTRIAL APPLICABILITY The present invention has a remarkable effect of obtaining a flame-retardant cloth having flame retardancy, good workability in handling, and high tensile strength.

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Claims (1)

Claim: What is claimed is: 1. A flame-retardant component containing at least 3 phosphorus elements.
A polyester fiber cloth containing 000 ppm to 10000 ppm, in which 40% by weight or less of a heat-bonding fiber is mixed with the cloth and fused, and the flame-retardant cloth is characterized.