KR102392712B1 - flame retarding non-woven for mattress and manufacturing method therof - Google Patents

Abstract

The present invention relates to a flame retardant non-woven fabric for a mattress that provides improved flame retardancy and mechanical properties as well as excellent restoration performance. The flame retardant non-woven fabric for a mattress according to the present invention comprises: 10-50 wt% of flame retardant (FR) rayon staple fibers; 10-50 wt% of modacrylic staple fibers; 10-40 wt% of elastic staple fibers; and 5-40 wt% of low-melting (LM) polyester staple fibers.

Description

Flame retarding non-woven for mattress and manufacturing method thereof

The present invention relates to a flame-retardant non-woven padding made of several fibers suitable for use in bed mattresses.

A mattress is generally placed on a bed frame constituting a bed used in each home, and is used for people to get a good night's sleep and rest.

The mattress is generally constructed by covering the outer circumferential surface of the tension element having its own tension force.

In general, the basic performance of a mattress is heat retention, ventilation, stability, and durability to maintain volume even after long-time use. That is, the mattress should provide warmth to maintain the user's body temperature and smooth ventilation of air inside and outside the mattress, and should have good contractility and restoration properties under the user's load.

Mattresses are generally rectangular in shape and generally consist of a core, upholstery and a cover.

The heart material has the greatest influence on the feel of the mattress, and springs, latex, and memory foam are used as materials. The interior material expresses various functions of the mattress between the core material and the cover. The cover is a part that is in direct contact with the body.

Since the interior material and cover affect the human body, antibacterial, sterilizing, and deodorizing functions are pursued, so there are no inconveniences or problems during use. However, if an unexpected fire occurs during use and a flame ignites on the mattress, the interior material and cover made of simple textile materials are easily incinerated. In addition, as toxic gases harmful to the human body are generated during incineration, there is a problem that a larger fire and human damage occur.

The interior material and the cover are generally manufactured by integrating with the known quilting method in a state in which the nonwoven padding and the fabric are laminated in the order from the inside to the outside, and the material used here is pointed out as the main factor in the spread of the mattress fire.

Accordingly, various fiber materials used for mattresses are required to be flame retardant.

Nonwoven fabric is used in mattresses because it has a great degree of freedom with respect to thickness, does not wrinkle, and can have heat retention.

Korean Patent Registration No. 0756557 discloses a flame-retardant nonwoven fabric using flame-retardant rayon single yarn. According to the above patent, nonwoven fabrics made of flame-retardant rayon single yarn, modacrylic single yarn and low melting point polyester single yarn showed flame retardancy, but other effects on heat retention, ventilation, restoration, and durability are not shown.

Therefore, research and development to ensure that various characteristics required for mattresses are expressed in a balanced way in addition to flame retardancy are continuously required.

An object of the present invention is to provide a nonwoven fabric for a mattress having a function suitable as an interior material for bedding while having a flame retardancy in order to respond to the requirements as described above, and a method for manufacturing the same.

The present invention in order to solve the above problems, flame-retardant rayon (FR-Rayon) short fibers 10 to 50% by weight, modacrylic (Modacrylic) short fibers 10 to 50% by weight, elastic fiber short fibers 10 to 40% by weight and low melting point It provides a flame retardant nonwoven fabric for mattresses comprising 5 to 40% by weight of polyester (Low Melting Polyester, LM PET) short fibers.

In addition, the present invention, flame-retardant rayon (FR-Rayon) short fibers 10 to 50% by weight, modacrylic (Modacrylic) short fibers 10 to 50% by weight, elastic fiber short fibers 10 to 40% by weight and low-melting polyester (Low Melting Polyester, LM PET) mixing including 5 to 40 wt% of short fibers; manufacturing a web by carding and laminating the fibers of the mixing step; And heat-treating the web; provides a method of manufacturing a flame-resistant nonwoven fabric for a mattress comprising.

According to the present invention, the nonwoven fabric formed by adding elastic fibers and low-melting polyester fibers to flame-retardant fibers can improve both flame retardancy and restoration properties.

Flame-retardant nonwoven fabric for mattress of the present invention, flame-retardant rayon (FR-Rayon) short fibers 10 to 50% by weight, modacrylic (Modacrylic) short fibers 10 to 50% by weight, elastic fiber short fibers 10 to 40% by weight and low-melting poly Ester (Low Melting Polyester, LM PET) is a nonwoven fabric comprising 5 to 40% by weight of short fibers.

Rayon fiber is widely used for lining of outerwear or underwear, has hygroscopicity, and is a textile material that can prevent user discomfort due to static electricity due to its excellent antistatic function and touch to prevent static electricity.

Flame-retardant rayon fiber is a fiber to which flame retardancy is imparted to rayon fiber, and can be manufactured by modifying it by adding a phosphorus-based flame retardant in the spinning step of rayon. Flame-retardant rayon fiber maintains the drape, absorbency, and feel of rayon, and has a high LOI, so the amount of smoke is small, there is no generation of harmful gas, it has durability in washing, and it can be dyed.

It is preferable to use the flame-retardant rayon fiber having a fineness of 0.5 to 15 denier and a length of 22 to 127 mm.

If the content of flame-retardant rayon fibers in the nonwoven fabric is less than 10% by weight, static electricity is generated when mixing to produce a nonwoven fabric, so that the mixing is not made uniformly and flexibility is lowered, and when it exceeds 50% by weight, the elasticity of the nonwoven fabric is reduced The flame retardancy is lowered because the fire does not go out immediately even if the fire is easily removed.

Modacrylic fiber is an acrylic synthetic fiber prepared from a polymer containing acrylonitrile as a main component. Preferably, the polymer is a copolymer comprising 30 to 60% by weight of acrylonitrile and 70 to 30% by weight of a halogen-containing vinyl monomer. The halogen-containing vinyl monomer is, for example, at least one monomer selected from vinyl chloride, vinylidene chloride, vinyl bromide, vinylidene bromide and the like. Examples of copolymerizable vinyl monomers include acrylic acid, methacrylic acid, salts or esters of such acids, acrylamide, methylacrylamide, vinyl acetate, and the like.

A preferred modacrylic fiber is a copolymer of acrylonitrile in combination with vinylidene chloride, which copolymer may additionally have antimony oxide or antimony oxides for improved flame retardancy.

Modacrylic produces a flame retardant gas as a barrier to oxygen during combustion.

Modacrylic fiber itself has excellent strength, elasticity, flame retardancy and chemical resistance. In addition, since the price is relatively low among the fibers having flame retardancy, it is widely used in work clothes, flame-retardant lab clothes, carpets, curtains, and the like. However, when exposed to sunlight, discoloration is easy to occur, dyeability is poor, and elasticity is poor during dyeing, which limits its use alone.

When the amount of modacrylic fiber in the nonwoven fabric is less than 10% by weight, the generation of flame retardant gas heavier than air, which suppresses contact between flammable substances and oxygen during combustion, is reduced, so that the flame retardancy decreases and the elasticity decreases, exceeding 50% by weight When burning, the heat resistance is low, the length of the carbonization (char) is increased, and a lot of harmful smoke is generated, which is harmful to the human body by inducing pollution, and it is easy to generate a nep in the mixing stage.

The elastic fiber short fibers may exhibit a cushioning feeling by improving rebound resilience and restoration properties in nonwoven padding made of only thermal bonding between fibers.

To this end, the short elastic fiber may be a polyester-based elastic composite fiber or a polyester-based elastic hollow fiber without limitation. An elastic hollow fiber, a sheath-core elastic composite fiber in which a material having elasticity is made of a sheath, a side-by-side (hollow) elastic composite fiber including a material having elasticity, etc. may be used.

Commercialized examples of the elastic fibers include E-Plex (Toray Advanced Materials Co., Ltd., Korea), EM-Elastic, ConJu, X-11, PolarFil, and EMF (above Huvis, Korea).

If the elastic fiber is less than 10% by weight in the nonwoven fabric of the present invention, rebound resilience and restoration properties may be reduced, and mechanical strength and flame retardancy may be reduced in excess of 40% by weight.

The low melting point polyester (LM PET) fiber has a melting point of 110 to 200° C., and is melted in the temperature range to exhibit a fusion function.

When manufacturing the nonwoven fabric, the low-melting polyester fiber serves as an adhesive by fusion in the heat treatment process to provide bonding strength between the fibers, thereby improving the mechanical strength, elasticity, and durability of the nonwoven fabric.

In addition, when burning, it is first melted and thermally decomposed to form a carbonized film in the nonwoven fabric. Since this carbonized film suppresses the shrinkage of the nonwoven fabric and forms a film that fills the pores of the nonwoven fabric, flame retardancy and flame retardancy are improved in the nonwoven fabric.

If the low-melting-point polyester fiber in the nonwoven fabric is less than 5% by weight, the mechanical strength and durability of the nonwoven fabric are reduced, and when it exceeds 40% by weight, the nonwoven fabric becomes hard by heat fusion and shrinks due to heat, resulting in rapid flame retardancy and flame retardancy. lowers

At this time, if the melting point of the low-melting-point polyester fiber is less than 110° C., deterioration and detachment of the properties of the low-melting-point polyester fiber may occur by the following wet heat treatment.

As the low-melting polyester fiber, it may be better to use graphene-coated ones.

The graphene-coated low-melting polyester fiber suppresses the generation of static electricity during mixing to facilitate mixing, promotes heat transfer in the heat treatment step of the present invention to provide uniform thermal adhesion and an outer surface, and an antibacterial nonwoven fabric can provide

The nonwoven fabric of the present invention has improved mechanical properties with flame retardancy even without additional flame retardant treatment.

The elastic fiber and the low-melting polyester fiber of the present invention have different fineness, crimp degree and crimp number ratio (crimp degree (%)/number of crimps (number/inch)), and crimping expression when applied to a mattress. Even after long-term use, it is possible to suppress a decrease in volume or a decrease in resilience and resilience, so that durability can be improved.

Crimp (%) = (B - A) x 100 / B

A : length in crimped state

B: The length of the crimped state by applying tension.

For this purpose, the elastic fiber is preferably a latent crimped yarn having a fineness of 4 to 12 denier, a ratio of crimp degree and number of crimps of 2 to 6, and a crimping force that increases the number of crimps by heat treatment, and the low melting point polyester fiber is preferably a latent crimp yarn having a fineness of 1 to 3 denier, a ratio of crimp degree to number of crimps of 1.2 to 1.8, and a crimping force that increases the number of crimps after heat treatment.

The crimping force is expressed as the number of crimps developed during no-load heat treatment by heat treatment at 170° C. in dry heat for 2 minutes. It is preferable that the latent crimped yarn of the present invention has at least 10 crimps/inch during no-load heat treatment by heat treatment at 170° C. in dry heat for 2 minutes. If the number of developed crimps is less than 10/inch, the elasticity may be lowered.

When the number of crimps expressed exceeds 50/inch, the degree of improvement in rebound resilience is insignificant.

The elastic fiber and the low-melting polyester fiber need to be different in the number of crimps expressed during no-load heat treatment by heat treatment at 170° C. in dry heat for 2 minutes, so it is preferable that the number of crimps differ by 10 pieces/inch or more.

If the fineness of the elastic fiber is less than 4 denier, rigidity and rebound resilience deteriorate and bulkiness decreases. If the ratio of is less than 2, the bulkiness of the nonwoven fabric is lowered, and when it exceeds 6, the number of crimps is low and the entanglement between fibers is weakened when forming a web with a card, and the quality of the nonwoven fabric may be deteriorated.

If the fineness of the low-melting polyester fiber is less than 1 denier, the card passability is bad, and if it exceeds 4 denier, the quality of the nonwoven may be deteriorated due to non-uniform fusion, and if the ratio of the degree of crimping to the number of crimps is less than 1.2, the bulkiness of the nonwoven fabric If this decreases and exceeds 1.8, the fusion may not be uniform and the quality of the nonwoven fabric may deteriorate.

At this time, it is preferable that the final number of crimps expressed after heat treatment of the elastic fibers and the low-melting polyester fibers is 15 pieces/inch or more.

In addition, it is more preferable that the elastic fiber is an elastic composite yarn formed of a side-by-side form of a polyester elastomer and polyethylene terephthalate.

The manufacturing method of the nonwoven fabric of the present invention, flame-retardant rayon (FR-Rayon) short fibers 10 to 50% by weight, modacrylic (Modacrylic) short fibers 10 to 50% by weight, elastic fiber short fibers 10 to 40% by weight and low-melting poly Ester (Low Melting Polyester, LM PET) comprising 5 to 40% by weight of short fibers mixing; manufacturing a web by carding and laminating the fibers of the mixing step; and heat-treating the web.

The flame-retardant rayon and modacrylic short fibers have a fineness of 0.5 to 15 d (denier) and a length of 22 to 127 mm. can

At this time, if the fineness of the short fibers is less than 0.5d, the mechanical strength of the nonwoven fabric is reduced, and if it exceeds 15d, the elasticity of the nonwoven fabric is reduced and it is difficult to obtain a high-density nonwoven fabric.

If the length of each of the short fibers is less than 22 mm, the mechanical strength is lowered, and if it exceeds 127 mm, the mechanical strength is increased, but the mixing is not made uniformly and the mixing workability is deteriorated.

In the present invention, in order to express the inherent mechanical properties of elastic fibers in the nonwoven fabric, it is preferable that the number of crimps of the short elastic fibers is 5 to 15 pieces/inch, but if the number of crimps is less than 5 pieces/inch, the elasticity of the nonwoven fabric decreases If it exceeds 15 pieces/inch, it is difficult to produce a uniform web when carding.

Friction occurs in machines, etc., in the processing process of elastic fibers, and it is easy to fibrillate due to such friction, and thus, the fibers are easy to fall out during processing.

In addition, since it is a synthetic fiber, static electricity is easily generated, and workability deteriorates due to deterioration of workability during mixing and carding.

In the present invention, in order to solve this problem, short elastic fibers treated with an emulsion may be used.

The short elastic fiber treated with the oil agent is a staple fiber having an oil agent adhesion amount of 0.5 to 1.0% by weight based on the weight of the fiber.

By using the short elastic fiber treated with the emulsion, a uniform web can be formed by suppressing the generation of static electricity during mixing and carding.

The emulsion is (A) 20 to 60% by weight of a fatty acid ester having a molecular weight of 200 to 500, (B) 0.5 to 5% by weight of dimethyl silicone, (C) 5 to 30% by weight of a quaternary ammonium salt type or amine type cationic active agent, and (D) it is preferable to include 15 to 50% by weight of the nonionic active agent.

The emulsion has improved smoothness by mixing a small amount of component (B) with component (A) as the main component, antistatic property is expressed by component (C), and has a limited emulsion form by component (D) thing becomes possible

The component (A) can impart smoothness to the short fibers.

If the molecular weight of the component (A) is less than 200, the viscosity is low and volatilization is easy, and if it exceeds 500, the viscosity increases and it is difficult to provide smoothness.

If the content of component (A) in the emulsion is less than 20% by weight, it is difficult to provide smoothness, and if it exceeds 60% by weight, it is difficult to provide an emulsion to the fibers because emulsification is not uniform.

Examples of the component (A) include methyl palmitate, methyl stearate, methyl oleate, butyl laurate, lauryl laurate, and the like.

If the content of component (B) in the emulsion is less than 0.5% by weight, the effect of improving smoothness is insignificant, and if it exceeds 5% by weight, the emulsification may not be uniform.

When the oil agent contains a small amount of component (B), smoothness may be further improved and the content of component (A) may be lowered. For this reason, by increasing the content of other components, it is possible to suppress the generation of static electricity during carding and improve the stability of the emulsion.

If the content of component (C) in the emulsion is less than 5% by weight, the antistatic effect is small, and when it exceeds 30% by weight, the viscosity increases and smoothness may decrease.

Examples of the component (C) include lauryltrimethylammonium chloride, lauryldimethylethylammonium chloride, and lauryldimethylethylammonium bromide.

If the component (D) in the oil agent is less than 15% by weight, it is difficult to prepare the oil agent as an aqueous emulsion, and if it exceeds 50% by weight, the smoothness is lowered, and fluff or single yarn may occur due to friction with the guide, and the quality of the fiber is deteriorated. .

Examples of the component (D) include ethylene oxide adducts of higher alcohols, ethylene oxide adducts of alkyl phenols, ethylene oxide adducts of fatty acids, ethylene oxide adducts of fats and oils, fatty acid esters of polyhydric alcohols, and the like. For example, ethylene oxide adduct of lauryl alcohol and oleyl alcohol, nonyl phenol and benzyl phenyl phenol, ethylene oxide adduct of tristyrenated phenol, ethylene oxide adduct of lauric acid and stearic acid, castor oil and hydrogenated castor oil ethylene oxide adduct, ethylene oxide adduct of glycerin, sorbitan, and lauric acid ester; and the like.

The short fibers treated with the emulsion have high smoothness, so it can be suppressed from being wound on a cylinder or a roller during the manufacturing process. This improves pass-through when carding and results in a web without thickness spots.

In addition, since the coefficient of kinetic friction of the web can be reduced, it is possible to obtain a nonwoven fabric having increased entanglement of fibers and increased density due to excellent mixing workability. In addition, there is provided a short fiber having less generation of static electricity during the process and excellent workability.

In addition, since the degree of freedom is increased by the emulsion treatment compared to other fibers constituting the nonwoven fabric, elasticity can be further improved.

In the heat treatment step of the present invention, by applying heat of 160 ~ 200 ℃, which is higher than the melting point of the low-melting polyester fiber, the entanglement between each fiber is made by the low-melting polyester fiber to complete the three-dimensional entanglement to obtain a nonwoven fabric with elasticity. there is.

In the heat treatment step, the low-melting-point fiber is melted to have adhesiveness, and by connecting the fibers of the nonwoven fabric, it has adhesiveness.

At this time, if the temperature is less than 160 ℃, the low-melting fiber deep inside the non-woven fabric does not melt, so the internal connectivity is lowered, resulting in a problem in that the strength and recovery of the non-woven fabric are lowered. Due to the decomposition of the low-melting fiber, the adhesiveness is lowered, and accordingly, the strength of the nonwoven fabric is lowered and recovery to its original state may not be easy.

In the present invention, by further carrying out the step of deoiling before the step of heat treatment, the adhesion amount of the oil agent in the nonwoven fabric can be adjusted to 0.3% or less based on the weight of the fibers constituting the nonwoven fabric.

When it exceeds 0.3%, the friction force between the fibers is small, and the mechanical properties may be deteriorated. That is, since the adhesion amount of the oil agent is reduced by the deoiling, the friction force between the fibers is increased to further improve the mechanical properties of the nonwoven fabric.

As a method of deoiling, washing, hot water washing, calender high temperature treatment, etc. can be used without limitation, but it is more preferable to perform wet heat treatment at 130 to 145 ° C. for 10 to 90 minutes in a high humidity atmosphere.

In this case, the wet heat treatment may be performed using high-pressure steam in an autoclave or in a high-pressure dyeing machine.

Due to the wet heat treatment, the flame-retardant rayon short fibers and modacrylic short fibers constituting the nonwoven fabric expand and soften by moisture and become plasticized. Wrinkles can be suppressed.

The nonwoven fabric of the present invention exhibits mechanical strength and durability while being lightweight with a basis weight of 200 to 1,000 g/m 2 .

The nonwoven fabric for the mattress of the present invention produced by the method as described above has flame-retardant properties while improving resilience and restoration properties. In addition, since the bonding strength between the constituent fibers of the nonwoven fabric is increased by the low melting point polyester fiber, the mechanical strength and durability of the nonwoven fabric are improved.

Hereinafter, the present invention will be described in more detail based on the following Examples and Comparative Examples.

However, the following examples are only for illustrating the present invention, and the present invention is not limited by the following examples, and can be substituted and changed to other equivalent examples without departing from the technical spirit of the present invention. It will be apparent to those of ordinary skill in the art to which the present invention pertains.

[Example 1]

Flame-retardant rayon short fiber (1d x 51 mm) 30 wt%, Modacrylic short fiber (2d x 51 mm) 30 wt%, elastic fiber short fiber (ConJu HCF (hollow), Huvis Co., Ltd., 2d x 51 mm, crimped 6 pieces/inch) 30% by weight and 10% by weight of LM PET short fibers (2d x 51 mm) having a melting point of 150° C. were mixed in the honta-myeon process. Thereafter, carding was performed on a roller card machine at a speed of 30 m/min to form a sheet-like web, which was laminated in multiple layers in a cross lay machine.

Thereafter, by heat-treating at 180° C. using a dryer and a heat treatment device, a flame-retardant nonwoven fabric of 500 g/m 2 was prepared.

[Example 2]

In Example 1, flame-retardant rayon short fibers 25% by weight, modacrylic short fibers 25% by weight, and the elastic fiber short fibers are side-by-side fibers (Polarfil, Huvis, 2d x 51 mm, number of crimps) 6 pieces/inch) A flame-retardant nonwoven fabric was prepared in the same manner as in Example 1, except that it was 40% by weight.

[Example 3]

In Example 1, the same as in Example 1, except that the elastic fiber short fiber was a fiber (EMF, Huvis, 6d x 51 mm, number of crimps 6/inch) formed in a side-by-side form. A flame retardant nonwoven fabric was prepared using the method.

[Example 4]

In Example 1, 40 wt% of methyl stearate, 3 wt% of dimethylsilicone having a viscosity of 10 mm / s, 25 wt% of lauryl trimethylammonium chloride and 5 moles of lauryl ether adduct of ethylene oxide to the short elastic fiber 32 A flame-retardant nonwoven fabric was prepared in the same manner as in Example 1, except that 0.8% of the emulsion composed of weight % was attached to the total weight of the elastic fibers.

[Example 5]

A flame-retardant nonwoven fabric was prepared in the same manner as in Example 1, except that in Example 4, wet heat treatment was performed at 140° C. for 30 minutes immediately before heat treatment so that the emulsion was attached to 0.25% of the weight of the elastic fibers constituting the nonwoven fabric. did

[Example 6]

In Example 1, the elastic fiber was made in a side-by-side form of polyester elastomer and polyethylene terephthalate, the number of crimps was 8 pieces/inch, the degree of crimping was 25% (ratio of the degree of crimping to the number of crimps, 3.1), and the fineness was is 6 denier, the number of crimps expressed after heat treatment (170° C., 2 minutes) is 25/inch, the number of crimps of the LM PET short fibers is 13/inch, and the degree of crimp is 20% (ratio of crimp to number of crimps) 1.5), a fineness of 2 denier, and a flame-retardant nonwoven fabric was prepared using the same method as in Example 1, except that the number of crimps expressed after heat treatment (170° C., 2 minutes) was 35/inch.

[Comparative Example 1]

In Example 1, flame-retardant rayon short fiber (1d x 51 mm) 42 wt%, modacrylic short fiber (2d x 51 mm) 40 wt%, elastic fiber short fiber (ConJu HCF (hollow), Huvis Co., Ltd., The same method as in Example 1 was used, except that 8 wt% of 2d x 51 mm, 6 crimps/inch) and 10 wt% of LM PET short fibers (2d x 51 mm) having a melting point of 150 ° C were used. was used to prepare a flame-retardant nonwoven fabric.

[Comparative Example 2]

In Example 1, flame-retardant rayon short fiber (1d x 51 mm) 23 wt%, modacrylic short fiber (2d x 51 mm) 22 wt%, elastic fiber short fiber (ConJu HCF (hollow), Huvis Co., Ltd., The same method as in Example 1 was used except that 45 wt% of 2d x 51 mm, 6 crimps/inch) and 10 wt% of LM PET short fibers (2d x 51 mm) having a melting point of 150 ° C were used. was used to prepare a flame-retardant nonwoven fabric.

[Comparative Example 3]

In Example 6, the elastic fiber is made of a side-by-side form of polyester elastomer and polyethylene terephthalate, the number of crimps is 8/inch, the fineness is 6 denier, and the number of crimps of the LM PET short fiber is 8/inch A flame-retardant nonwoven fabric was prepared in the same manner as in Example 6, except that it was in inches and had a fineness of 6 denier.

The nonwoven fabric according to the Examples and Comparative Examples and the workability for producing the same were evaluated as follows and shown in Tables 1 to 3.

<Evaluation method>

1. Flame retardant

1-1. It is measured by KOFEIS 1001, the Korean flame retardant performance standard.

1-2. The heat release rate is measured by CPSC FR 1633 or KS F ISO 12949, which is a test method for bed mattresses and mattress sets.

At this time, the maximum heat release rate (peak HRR) is 200 kW or less, and the total heat release rate (THR _10min ) for 10 minutes is 15 MJ or less as the standard for the mattress.

2. Carding equipment passability

During carding, the state in which the fibers are wound on the cylinder and the uniformity of the resulting web are observed and evaluated.

A case in which needle punching could not be smoothly performed due to a very poor web was evaluated as ×, a case in which it was smoothed was evaluated as ○, and a middle one was determined as △.

3. Static electricity generation in carding equipment

The amount of static electricity (kV) was measured with a static electricity meter at a distance of 10 cm from the web between the doffer and the take-up roller under the conditions of 25° C. and 45% RH.

4. Tensile strength

It is measured according to the Korean Industrial Standards KS G 4300: 2020.

5. Resilience

A 25Kg weight covering the entire specimen is placed on a 250 mm X 250 mm specimen for a certain period of time (3, 24, 72, 120 hours) and removed to measure the change in thickness in %.

On the other hand, the change rate of the thickness is measured in % after 50 cycles of putting the weight on for 8 hours and removing the weight for 8 hours as one cycle.

division Afterflame time (sec)
(Afterflame time) remaining time (seconds)
(Afterglow time) Carbonization area (㎠)
(Carbonized area) Carbonization length (cm)
(Char length) Based on KOFEIS 1001 within 5 seconds within 20 seconds within 40cm2 within 20cm Example 1 2 9 27 12.8 Example 2 3 12 28 15.2 Example 3 2 8 26 12.2 Example 4 2 9 29 13.2 Example 6 2 9 26 12.5 Comparative Example 1 One 3 21 11.7 Comparative Example 2 6 21 46 21.3 Comparative Example 3 2 9 26 12.6

Maximum heat release rate Total heat dissipation (10 minutes) KS F ISO 12949 standard 200 kW or less 15 MJ or less Example 1 97 5.4 Example 2 104 5.9 Example 3 95 5.3 Example 4 98 5.6 Example 6 96 5.3 Comparative Example 2 212 16.8

From the flame retardancy test results in Tables 1 and 2, it is confirmed that when the elastic fiber according to the present invention is contained, it exhibits a flame retardancy suitable for the mattress. is confirmed

Example 1 Example 4 Example 5 card machine passability △ ○ ○ card machine static electricity
Generation (kV) 2.3 0.5 0.5

From the results of Examples 4 and 5 in Table 3, it is confirmed that carding is facilitated when the elastic fiber treated with the oil agent of the present invention is used.

On the other hand, it was observed that when short fibers not treated with tanning were used, openability was not good, and some adhesion to the roll occurred, resulting in the formation of a non-uniform web.

3 hours 24 hours 72 hours 120 hours 50 cycles Example 1 60% 51% 47% 44% 39% Example 2 57% 49% 47% 46% 40% Example 3 62% 52% 47% 46% 41% Example 4 86% 73% 69% 65% 60% Example 6 82% 68% 64% 61% 59% Comparative Example 1 49% 41% 36% 33% 29% Comparative Example 2 88% 75% 72% 68% 65% Comparative Example 3 74% 64% 58% 55% 49%

From the stability evaluation results in Table 4, it is confirmed that when the elastic fiber according to the present invention is used, the recovery property is improved. When the content of the elastic fiber is too large, it is also confirmed that the flame retardancy is lowered.

In addition, it is confirmed that the nonwoven fabric with different fineness and number of crimps of elastic fibers and low-melting polyester fibers has improved stability in 50 cycles of load (8 hours)-non-load (8 hours). It can be seen that even when applied and used, the durability of restoration property is excellent compared to other nonwoven fabrics.

On the other hand, in Example 5, a nonwoven fabric having a uniform surface and significantly suppressed occurrence of wrinkles on the outer surface of the nonwoven fabric was prepared. From this, it is confirmed that each fiber constituting the nonwoven fabric is due to plasticization by the previous wet heat treatment when passing through the heat treatment apparatus.

Claims (7)

Flame-retardant rayon (FR-Rayon) short fibers 10 to 50% by weight, Modacrylic short fibers 10 to 50% by weight, elastic fibers short fibers 10 to 40% by weight, and Low Melting Polyester (LM PET) Contains 5 to 40% by weight of short fibers,
The elastic fiber short fibers, methyl stearate 20 to 60% by weight, dimethyl silicon 0.5 to 5% by weight, lauryl trimethylammonium chloride 5 to 30% by weight, and lauryl ether ethylene oxide 5 mol adduct 15 to 50% by weight Flame-retardant nonwoven fabric for mattresses, characterized in that the content of the emulsion is 1.0% or less based on the weight of the elastic fiber by being treated with an oil comprising: The method of claim 1,
The flame retardant nonwoven fabric for the mattress has a maximum heat release rate (peak HRR) of 120 kW or less, and a total heat release (THR _10min ) for 10 minutes is 10 MJ or less (Korean mattress test KS F ISO 12949 method) Flame retardant for mattresses Non-woven. The method of claim 1,
The elastic fiber is a polyester-based elastic composite fiber formed in a sheath-core form or side-by-side form, or a flame-retardant nonwoven fabric for a mattress, characterized in that it is a polyester-based elastic hollow fiber. Flame-retardant rayon (FR-Rayon) short fibers 10 to 50% by weight, Modacrylic short fibers 10 to 50% by weight, elastic fibers short fibers 10 to 40% by weight, and Low Melting Polyester (LM PET) Mixing including 5 to 40% by weight of short fibers; manufacturing a web by carding and laminating the fibers of the mixing step; and heat-treating the web.
The elastic fiber short fibers, methyl stearate 20 to 60% by weight, dimethyl silicon 0.5 to 5% by weight, lauryl trimethylammonium chloride 5 to 30% by weight, and lauryl ether ethylene oxide 5 mol adduct 15 to 50% by weight A method of manufacturing a flame-retardant nonwoven fabric for a mattress, characterized in that it is manufactured by treatment with an emulsion comprising a. 5. The method of claim 4,
Method for producing a flame-retardant nonwoven fabric for mattress, characterized in that it further comprises the step of deoiling the emulsion immediately before the step of heat-treating the web. delete 6. The method of claim 5,
The method of manufacturing a flame-retardant nonwoven fabric for a mattress, characterized in that the adhesion amount of the oil agent after the deoiling step is 0.3% or less by weight of the elastic fibers constituting the nonwoven fabric.