KR102392713B1 - 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 and, more specifically, to a flame retardant non-woven felt fabric for a mattress that provides improved flame retardancy, mechanical properties, restoration performance and durability. The flame retardant non-woven felt fabric for a mattress comprises: 65-95 wt% of flame retardant (FR) rayon staple fibers; and 5-35 wt% of low-melting polyester staple fibers including a polyester elastomer as a thermal fusing component.

Description

Flame retarding non-woven for mattress and manufacturing method thereof

The present invention relates to a flame-retardant nonwoven felt 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.

In order to solve the above problems, the present invention comprises 65 to 95% by weight of flame-retardant rayon (FR-Rayon) short fibers, and 5 to 35% by weight of low-melting polyester short fibers including polyester elastomer as a heat-sealing component. A flame-retardant nonwoven fabric for mattresses is provided.

In addition, the present invention, flame-retardant rayon (FR-Rayon) short fibers 40 to 80% by weight, modacrylic short fibers 10 to 50% by weight, and low-melting polyester short fibers 5 to 35 including polyester elastomer as a heat-sealing component It provides a flame-retardant nonwoven fabric for a mattress comprising a weight %.

On the other hand, the present invention, flame-retardant rayon (FR-Rayon) comprising the steps of mixing 65 to 95% by weight of short fibers and 5 to 35% by weight of low-melting polyester short fibers including polyester elastomer; manufacturing a web by carding and laminating the fibers of the mixing step; needle punching the web; And heat-treating the web; provides a method of manufacturing a flame-retardant nonwoven fabric for a mattress comprising.

According to the present invention, the nonwoven fabric is made of flame-retardant rayon short fibers and low-melting polyester short fibers, thereby making it possible to be applied to a mattress to be excellent in flame retardancy, mechanical properties, restoration properties and durability.

The flame-retardant nonwoven fabric for mattress of the present invention comprises 65 to 95% by weight of flame-retardant rayon (FR-Rayon) short fibers and 5 to 35% by weight of low-melting polyester (LM PET) short fibers as a heat-sealing component. made of non-woven fabric.

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.

Since flame-retardant rayon fibers do not have a melting point, the generation of drips during combustion may be reduced.

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 fineness is less than 0.5 denier, the bulkiness deteriorates and cushioning properties and repulsion properties are lowered, and if the fineness exceeds 15 denier, it is difficult to make a web, and the number of fibers constituting the nonwoven fabric at the same basis weight is small, and the cushioning property may be reduced.

The flame-retardant rayon fiber preferably has a crimp number of 5 to 15 pieces/inch and a crimp rate of 20 to 35%. If it is larger than this range, the entanglement of the short fibers may become too large, making the carding operation difficult.

If the content of the flame-retardant rayon fibers in the nonwoven fabric is less than 65% by weight, the flame retardancy is reduced, and when it exceeds 95% by weight, the adhesion between the fibers is insufficient, so that the mechanical strength may decrease and the shrinkage rate may decrease.

The low-melting polyester (LM PET) fiber has a fusion component having 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 is 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 is reduced, and when it exceeds 35% by weight, the nonwoven fabric is hardened by heat fusion and shrinkage due to heat occurs, thereby reducing shape stability.

At this time, if the melting point of the low-melting-point polyester fiber is less than 110° C., it is difficult to set the conditions for thermal bonding between the fibers, and the heat resistance is lowered.

As the low-melting polyester fiber, it is more preferable to use a composite fiber including a polyester-based elastomer as a heat-sealing component because it has heat resistance and can be thermoformed at a high temperature.

The polyester-based elastomer is preferably a block copolymer ether ester containing polybutylene terephthalate as a hard segment and polyoxybutylene glycol as a soft segment in terms of adhesion to other short fibers, temperature characteristics, and strength.

The low-melting polyester fiber is, for example, 38% by weight of polybutylene terephthalate and 62% by weight of polytetramethylene glycol obtained by polymerization of butylene glycol with an acid component mixed with terephthalic acid and isophthalic acid (80/20 mol%) % and block copolymerized polyether polyester, which is a thermoplastic elastomer having a melting point of 155° C., as a sheath component, and polyethylene terephthalate as a core component, may be used.

The composite fiber has a heat-sealing component exposed on the surface, and may be in the form of a side-by-side (parallel) type, a core sheath type, or an eccentric sheath type.

It is preferable that the ratio of the heat-sealing component in the composite fiber is 20 to 50% by weight. If it is less than 20% by weight, the cushioning property of the nonwoven fabric may decrease, and if it exceeds 50% by weight, the shrinkage of the nonwoven fabric (dry heat treatment at 300℃ for 10 seconds) case) outside the scope of the present invention, the combustion may be prolonged.

It is preferable that the fineness of the low-melting polyester fiber is 1 to 10 denier, the length is 22 to 127 mm, and the number of crimps is 4 to 30 pieces/inch. and cushioning properties and compression durability may decrease.

The low-melting polyester short fibers preferably contain 0.1 to 1.0% by weight of the organic phosphorus-based flame retardant based on the weight of the fiber.

By providing the flame retardant in this way, even if the content of the heat-sealing component in the low-melting polyester fiber increases, the shrinkage rate (when dry heat treatment is performed at 300°C for 10 seconds) can be within the range of the present invention, and the combustion time can be shortened. .

Also, the occurrence of drips may be reduced.

The organophosphorus flame retardant may be polyphosphoric acid carbamate or the like.

The low-melting polyester fiber of the present invention improves the entanglement of crimped glass fibers to be described later, so that even when applied to a mattress, which is a final product, it is possible to suppress the loss of fibers.

The flame-retardant nonwoven fabric for mattresses of the present invention is good because when dry heat treatment at 300° C. for 10 seconds, the shrinkage rate of 10 to 30% is ignited, and the combustion time can be shortened by shrinking away from the ignition source.

(Method of measuring shrinkage)

After heat-treating a specimen with a size of 150 mm on the long side and 50 mm on the short side in an electric furnace at 300°C for 10 seconds, measure the length of the long side, and calculate the shrinkage (%) by the following formula.

Shrinkage (%)=(L ₀ - L ₁ ) x 100 / L ₀

Here, L ₀ is the length of the long side of the specimen before heat treatment (mm), and L ₀₁ is the length of the long side of the specimen after heat treatment (mm).

In addition, the flame-retardant nonwoven fabric for the mattress of the present invention is a low-melting polyester including 40 to 80% by weight of flame-retardant rayon (FR-Rayon) short fibers, 10 to 50% by weight of modacrylic short fibers and a polyester-based elastomer as a heat-sealing component. It is a flame-retardant nonwoven fabric for mattresses comprising 5 to 35% by weight of short fibers.

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. However, it also produces significant amounts of acid gases.

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 inhibits contact between flammable substances and oxygen during combustion, is reduced, so flame retardancy and flame retardancy (flame retardation) are reduced, and elasticity is reduced. , when it exceeds 50% by weight, when burning, the heat resistance is low, the length of carbonization (char) is increased, and a lot of harmful smoke is generated, which is harmful to the human body and causes pollution, and neps are generated in the mixing stage easy to do

In addition, the nonwoven fabric of the present invention may be one in which a functional fiber having an elastic function is further added.

Examples of commercialized products of functional fibers having the elastic function include Conju and EMF of Huvis.

On the other hand, the nonwoven fabric of the present invention contains 5 to 20 parts by weight of crimped glass fiber compared to 100 parts by weight of the organic fiber composed of the flame-retardant rayon fiber and the low-melting fiber, or the organic fiber composed of the flame-retardant rayon fiber, the modacrylic fiber, and the low-melting fiber. What is added is more preferable because the generation of toxic gas is reduced, heat insulation, flame retardancy and abrasion resistance are improved, moisture absorption is suppressed, while flexibility and flexibility are not impaired.

In addition, since the crimped glass fiber has crimping, it is easy to mix, thereby suppressing drop-off from the nonwoven fabric, which is a final product, and improving the card formation degree due to passability during carding, thereby improving the yield of raw materials.

When the amount of the crimped glass fiber is less than 5 parts by weight, the degree of improvement in flame retardancy and the degree of reduction of toxic gas are insignificant, and when it exceeds 20 parts by weight, flexibility and flexibility may be reduced.

At this time, it is more preferable to use the crimped glass fiber that has been water-repellent before forming the card web.

As a result, the volume control becomes easier and the use efficiency of the water-repellent agent is improved compared to the water-repellent treatment of the formed nonwoven fabric.

The water-repellent process can be carried out so that a predetermined amount of a conventional water-based fluorine-based water-repellent agent is applied by a conventional method such as spraying, and then dried sufficiently so that the adhesion amount of the water-repellent agent is 2% by weight or less.

The manufacturing method of the nonwoven fabric of the present invention comprises the steps of mixing 65 to 95% by weight of flame-retardant rayon (FR-Rayon) short fibers and 5 to 35% by weight of low-melting polyester (LM PET) short fibers; manufacturing a web by carding and laminating the fibers of the mixing step; needle punching the web; and heat-treating the web.

In addition, the manufacturing method of the nonwoven fabric of the present invention, flame-retardant rayon (FR-Rayon) short fibers 40 to 80% by weight, modacrylic short fibers 10 to 50% by weight and low melting point polyester (Low Melting Polyester, LM PET) short fibers 5 to 35% by weight, including mixing; manufacturing a web by carding and laminating the fibers of the mixing step; needle punching the web; and heat-treating the web.

In the process of processing, friction occurs in machines, etc., and by such friction, it is easy to fibrillate, and thus, it is easy to cause the fibers to fall out during the 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 fibers subjected to emulsion treatment may be used.

The oil agent-treated short fibers are short fibers having an oil agent adhesion amount of 0.5 to 1.0 wt% based on the weight of the fiber.

By using the short fibers subjected to the emulsion treatment, 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, and lauryl laurate.

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.

The needle punching step of the present invention can be used without limitation by a conventional method.

The heat treatment step of the present invention is to improve the binding force of the fibers constituting the nonwoven fabric by the low melting point polyester.

For the heat treatment of the present invention, a conventional method can be used, but by passing the formed web under pressure in a calender roll device, it is more preferable to impart smoothness and achieve thermal bonding between the fibers constituting the web. good. Due to this, the shape of the nonwoven fabric, which is the final product, can be stably maintained.

The heat bonding temperature is set higher than the melting temperature of the low melting point polyester fiber so that the low melting point polyester fiber is melted to bond the flame retardant fiber.

The heat treatment is preferably performed by repeatedly passing the needle-punched web through a calender roll at least three times. At this time, by increasing the temperature of the calender rolls sequentially, 10~20 ℃ (primary calender roll), 20~30 ℃ (second calendering roll) and 30~40 ℃ (tertiary calendering roll) higher than the melting temperature of the low-melting polyester fiber ), it is more preferable to heat-seal it high.

In the present invention, by further performing the step of deoiling after the step of needle punching and 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 relative to 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, since the flame-retardant rayon short fibers constituting the nonwoven fabric expand and soften by moisture and become plasticized, wrinkles occurring due to the difference in properties of each fiber constituting the nonwoven fabric when passing through the calendering device in the heat treatment step This 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 mattress according to the present invention as described above has improved flame retardancy and a shorter combustion time. 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 replaced 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 staple fiber (2d x 51 mm, number of crimps 10 pieces/inch, crimp rate 33%) 80 wt%, LM PET staple fiber (6d x 51 mm, number of crimps number 13 pieces/inch, crimp rate 30%) 20 weight % of the raw material was mixed in the honta-myeon process.

At this time, in the LM PET short fiber, a polyester-based elastomer having a melting point of 155° C. as a fusion component constitutes a sheath component, and polyethylene terephthalate having a melting point of 256° C. constitutes a core component, the sheath component is 30%, and the core component is 70 % of the core-sheath type composite fiber was used.

After that, the web was manufactured with a conventional card machine, laminated with a conventional cross lacing machine, and the fibers were entangled by needle punching in a needle punching process.

Thereafter, by heat treatment at a temperature of 170 ° C., 180 ° C. and 190 ° C. sequentially using a heat treatment device, 425 g/m 2 of flame-retardant nonwoven felt was prepared.

[Example 2]

In Example 1, a flame-retardant nonwoven felt was prepared in the same manner as in Example 1, except that the LM PET short fibers had a sheath component of 50% and a core component type composite fiber having a core component of 50% was used.

[Example 3]

In Example 2, the LM PET short fibers were treated with a flame retardant containing polyphosphate carbamate as a main component, so that 0.5 wt% of the phosphorus component was used. A nonwoven felt was prepared.

[Example 4]

In Example 1, 40 wt% of methyl stearate, 3 wt% of dimethyl silicon having a viscosity of 10 mm / s, 25 wt% of lauryl trimethylammonium chloride and 5 moles of ethylene oxide adduct of flame retardant rayon short fiber 32 A flame-retardant nonwoven felt 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 flame-retardant rayon short fibers.

[Example 5]

Flame-retardant nonwoven fabric using the same method as in Example 4, except that in Example 4, moist 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 flame retardant rayon short fibers constituting the nonwoven fabric. A felt was made.

[Example 6]

In Example 1, based on 100 parts by weight of organic fibers composed of flame-retardant rayon short fibers and LM PET short fibers, a predetermined amount of a water-based fluorine-based water repellent was attached by a spray method and dried by heating, so that the water repellent agent adhesion amount was 2% by weight A flame-retardant nonwoven felt was prepared using the same method as in Example 1, except that 10 parts by weight of crimped glass fiber treated with water repellency was added to the organic fiber and mixed so as to become .

[Example 7]

Flame-retardant rayon staple fibers (2d x 51 mm, number of crimps 10 pieces/inch, crimp ratio 33%) 50% by weight, modacrylic staple fibers (2d x 51 mm) 30% by weight and LM PET staple fibers (6d x 51 mm, 13 crimps/inch, crimp rate 30%) 20% by weight of raw materials were mixed in the honta-myeon process.

At this time, in the LM PET short fiber, a polyester-based elastomer having a melting point of 155° C. as a fusion component constitutes a sheath component, and polyethylene terephthalate having a melting point of 256° C. constitutes a core component, the sheath component is 30%, and the core component is 70 % of the core-sheath type composite fiber was used.

After that, the web was manufactured with a conventional card machine, laminated with a conventional cross lacing machine, and the fibers were entangled by needle punching in a needle punching process.

Thereafter, by heat treatment at a temperature of 170 ° C., 180 ° C. and 190 ° C. sequentially using a heat treatment device, 425 g/m 2 of flame-retardant nonwoven felt was prepared.

[Comparative Example 1]

In Example 1, a flame-retardant nonwoven fabric was prepared in the same manner as in Example 1, except that 50% by weight of flame-retardant rayon short fibers and 50% by weight of LM PET short fibers were used.

[Comparative Example 2]

In Example 1, a flame-retardant nonwoven felt was prepared in the same manner as in Example 1, except that the LM PET short fibers had a sheath component of 60% and a core component type composite fiber having a core component of 40%.

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. 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.

1-2. Flammability is evaluated according to KS M 3809 standard.

2. Carding equipment passability

During carding, the state in which the fibers are wound around 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.

Maximum heat release rate Total heat dissipation (10 minutes) KS F ISO 12949 standard 200 kW or less 15 MJ or less Example 1 95 5.2 Example 2 96 5.3 Example 3 91 5.0 Example 6 87 4.6 Example 7 91 4.9 Comparative Example 1 224 17.1 Comparative Example 2 156 11.7

Combustion length (mm) Burning time (sec) number of drips Shrinkage (%) Example 1 9 2 0 22 Example 2 11 2 0 11 Example 3 7 One 0 16 Example 6 4 0 0 10 Example 7 8 2 0 23 Comparative Example 1 32 39 9 6 Comparative Example 2 23 29 3 8

From the flame retardancy test results of Tables 1 and 2, it is confirmed that the nonwoven fabric according to the present invention exhibits a flame retardancy suitable for a mattress. .

Example 1 Example 4 Example 5 card machine passability △ ○ ○ card machine static electricity
Generation (kV) 2.4 0.6 0.6

From the results of Examples 4 and 5 in Table 3, it is confirmed that carding becomes easy when the 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 92% 78% 74% 72% 71% Example 2 87% 74% 70% 68% 67% Example 3 86% 73% 70% 68% 67% Example 6 82% 71% 68% 66% 65% Comparative Example 1 73% 63% 57% 54% 48% Comparative Example 2 75% 65% 59% 56% 50%

From the stability evaluation results in Table 4, it is confirmed that the recovery properties are excellent when the nonwoven felt according to the present invention is used.

In addition, it can be seen that the durability is excellent compared to other nonwoven fabrics even when applied to a mattress for a long period of time because it has excellent cycle recovery properties of repeated use.

On the other hand, the nonwoven fabric of Comparative Example 1 exhibited low recovery properties and strong hardness compared with those of Examples.

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.

On the other hand, since the nonwoven fabric of Example 7 has increased elasticity compared to the nonwoven fabric of Example 1, it becomes possible to facilitate the operation when making a mattress structure.

Claims (10)

It contains 65 to 95% by weight of flame-retardant rayon (FR-Rayon) short fibers and 5 to 35% by weight of low-melting polyester short fibers including polyester elastomer as a heat-sealing component,
The flame-retardant rayon short fiber is, methyl stearate 20-60 wt%, dimethyl silicone 0.5-5 wt%, lauryl trimethylammonium chloride 5-30 wt%, and lauryl ether 5 mol adduct of ethylene oxide 15-50 wt% Flame-retardant nonwoven fabric for a mattress, characterized in that it is treated with an emulsion comprising It contains 40 to 80% by weight of flame-retardant rayon (FR-Rayon) short fibers, 10 to 50% by weight of modacrylic short fibers, and 5 to 35% by weight of low-melting polyester short fibers including polyester-based elastomer as a heat-sealing component,
The flame-retardant rayon short fiber is, methyl stearate 20-60 wt%, dimethyl silicone 0.5-5 wt%, lauryl trimethylammonium chloride 5-30 wt%, and lauryl ether 5 mol adduct of ethylene oxide 15-50 wt% Flame-retardant nonwoven fabric for mattresses, characterized in that it is treated with an emulsion 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 flame-retardant non-woven fabric for mattresses is a flame-retardant non-woven fabric for mattresses, characterized in that the shrinkage rate is 10 to 30% when dry heat treatment is performed at 300° C. for 10 seconds. The method of claim 1,
The polyester-based elastomer has a melting point of 110 to 200° C., and the low-melting polyester short fiber is a flame-retardant nonwoven fabric for a mattress, characterized in that it is formed in a sheath-core form or side-by-side form. The method of claim 1,
The low-melting polyester short fibers are flame-retardant nonwoven fabric for mattresses, characterized in that the polyphosphate carbamate flame retardant is contained in an amount of 0.1 to 1.0% by weight based on the weight of the fiber. Mixing including 65 to 95% by weight of flame-retardant rayon (FR-Rayon) short fibers and 5 to 35% by weight of low-melting polyester short fibers including a polyester-based elastomer as a heat-sealing component; manufacturing a web by carding and laminating the fibers of the mixing step; needle punching the web; and heat-treating the web.
The flame-retardant rayon short fiber is, methyl stearate 20-60 wt%, dimethyl silicone 0.5-5 wt%, lauryl trimethylammonium chloride 5-30 wt%, and lauryl ether 5 mol adduct of ethylene oxide 15-50 wt% 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. 8. The method of claim 7,
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 9. The method of claim 8,
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 based on the weight of the flame-retardant rayon short fibers constituting the nonwoven fabric.