KR20230137873A - Fabric, fabric body and sheet - Google Patents

Abstract

Provided are fabrics, fabric bodies, and sheets that exhibit excellent appearance, seating comfort, and breathability, and also exhibit excellent flame retardancy.
Containing 50% by mass or more of monofilament, the monofilament is a core-sheath composite fiber having a core portion and a sheath portion, and the core portion contains 60 to 90% by volume relative to the core-sheath composite fiber, and also contains a first flame retardant and a polyester elastomer, A fabric in which the sheath contains 10 to 40% by volume of the core-sheath composite fiber and is made of polyester excluding the polyester elastomer in the core.

Description

Fabric, fabric body and sheet

The present invention relates to fabrics, fabric bodies, and sheets. More specifically, the present invention relates to fabrics, fabric bodies, and sheets having good seating comfort, flame retardancy, and breathability.

Conventionally, a fabric for attaching to a frame and a seating seat with the fabric attached to a frame have been developed (Patent Document 1).

Japanese Patent Publication No. 2019-143283

The fabric of the seating seat is required to be flame retardant so that flames do not spread in the event of a fire, for example. However, the fabric and seating sheet described in Patent Document 1 do not disclose that they provide flame retardancy. Additionally, in order to impart flame retardancy to the fabric, it is conceivable to impart a flame retardant. However, flame retardants may appear on the surface as scum during spinning or flaking processes. As a result, there are problems such as variations in the amount of flame retardant contained in the fabric, poor appearance, or inability to provide the desired flame retardancy.

The present invention has been made in view of these conventional problems, and its purpose is to provide a fabric, fabric body, and sheet that exhibit excellent appearance, seating comfort, and breathability, and also exhibit excellent flame retardancy.

One form of fabric of the present invention that solves the above problem contains 50% by mass or more of monofilament, the monofilament is a core-sheath composite fiber having a core section and a sheath section, and the core section is the core sheath It contains 60 to 90% by volume based on the composite fiber, and also includes a first flame retardant and a polyester elastomer, and the sheath portion contains 10 to 40% by volume relative to the core sheath composite fiber, and further includes the polyester elastomer in the core portion. It is a fabric made of polyester.

Additionally, one type of fabric body of the present invention that solves the above problems is a fabric body having the above fabric and a frame member.

Additionally, one type of sheet of the present invention that solves the above problems is a sheet using the above fabric body.

Figure 1 is a schematic diagram for explaining a method of attaching a frame member to a fabric.
Figure 2 is a schematic diagram of a fabric body.

(Fabric and fabric body)

The fabric of one embodiment of the present invention contains 50% by mass or more of monofilament. Monofilament is a core-sheath composite fiber with a core and a sheath. The core portion contains 60 to 90% by volume of the core-sheath composite fiber, and also contains a first flame retardant and a polyester elastomer. The sheath contains 10 to 40% by volume of the core-sheath composite fiber and is made of polyester excluding the polyester elastomer of the core.

Additionally, the fabric body of one embodiment of the present invention has the fabric described above and a frame member. Below, each is explained.

(Four hundred)

The fabric contains 50% by mass or more of monofilament. Monofilament is a core-sheath composite fiber with a core and a sheath.

(heart)

The core includes a first flame retardant and a polyester elastomer.

(polyester elastomer)

The polyester elastomer is not particularly limited. For example, the polyester elastomer is a thermoplastic polyester elastomer, etc. Thermoplastic polyester elastomer resins include, for example, a high-melting point crystalline segment whose main structural unit is a crystalline aromatic polyester, and a low-melting point polymer segment whose main structural unit is an aliphatic polyether unit and/or an aliphatic polyester unit. It can be done as a component.

(high melting point crystalline segment)

The high-melting point crystalline segment is a polyester formed of aromatic dicarboxylic acid or its ester-forming derivative (hereinafter also referred to as “acid component”) and diol or its ester-forming derivative (hereinafter also referred to as “diol component”). am.

Aromatic dicarboxylic acids include, for example, terephthalic acid, isophthalic acid, phthalic acid, naphthalene-2,6-dicarboxylic acid, naphthalene-2,7-dicarboxylic acid, anthracenedicarboxylic acid, and diphenyl-4,4. '-dicarboxylic acid, diphenoxyethane dicarboxylic acid, 4,4'-diphenyl ether dicarboxylic acid, 5-sulfoisophthalic acid, and sodium 3-sulfoisophthalate.

In this embodiment, aromatic dicarboxylic acids can mainly be used. Some of the aromatic dicarboxylic acids include alicyclic dicarboxylic acids such as 1,4-cyclohexanedicarboxylic acid, cyclopentanedicarboxylic acid, and 4,4'-dicyclohexyldicarboxylic acid, and adiph It may be replaced with an aliphatic dicarboxylic acid such as acid, succinic acid, oxalic acid, sebacic acid, dodecanedioic acid, and dimer acid. Ester-forming derivatives of dicarboxylic acids (for example, lower alkyl esters, aryl esters, carbonic acid esters, and acid halides) may be used.

The diol is, for example, a diol with a molecular weight of 400 or less. Diols with a molecular weight of 400 or less include aliphatic diols such as 1,4-butanediol, ethylene glycol, trimethylene glycol, pentamethylene glycol, hexamethylene glycol, neopentyl glycol, and decamethylene glycol, 1,1-cyclohexanedimethanol, 1, Alicyclic diols such as 4-dicyclohexanedimethanol and tricyclodecane dimethanol, xylylene glycol, bis(p-hydroxy)diphenyl, bis(p-hydroxy)diphenylpropane, 2,2'- Bis[4-(2-hydroxyethoxy)phenyl]propane, bis[4-(2-hydroxyethoxy)phenyl]sulfone, 1,1-bis[4-(2-hydroxyethoxy)phenyl] and aromatic diols such as cyclohexane, 4,4'-dihydroxy-p-terphenyl, and 4,4'-dihydroxy-p-terphenyl. These diols can also be used in the form of ester-forming derivatives (e.g., acetyl forms, alkali metal salts, etc.).

(low melting point polymer segment)

The low melting point polymer segment is at least either aliphatic polyether or aliphatic polyester.

Aliphatic polyethers include poly(oxyethylene) glycol, poly(oxypropylene) glycol, poly(oxytrimethylene) glycol, poly(oxytetramethylene) glycol, poly(oxyhexamethylene) glycol, and ethylene of poly(oxypropylene) glycol. These include oxide adducts and copolymers of ethylene oxide and tetrahydrofuran. Among these, the aliphatic polyether is preferably poly(oxytetramethylene) glycol and/or an ethylene oxide adduct of poly(oxypropylene) glycol and/or a copolymer of ethylene oxide and tetrahydrofuran.

Aliphatic polyesters include poly(ε-caprolactone), polyenantholactone, polycaprylolactone, polybutylene adipate, and polyethylene adipate.

The low melting point polymer segment is poly(oxytetramethylene) glycol, ethylene oxide adduct of poly(oxypropylene) glycol, copolymer glycol of ethylene oxide and tetrahydrofuran, since the resulting polyester block copolymer has excellent elastic properties. , poly(ε-caprolactone), polybutylene adipate, polyethylene adipate, etc. are preferable, poly(oxytetramethylene) glycol, ethylene oxide adduct of poly(oxypropylene) glycol, and ethylene oxide and tetrahydrofuran. It is more preferable that it is a copolymer glycol.

The number average molecular weight of the low melting point polymer segment is preferably 300 to 6000 in a copolymerized state, and more preferably 1000 to 3000. When the number average molecular weight of the low melting point polymer segment is within the above range, the resulting fabric has excellent sag resistance, thus improving durability and providing better seating comfort.

Returning to the overall description of the polyester elastomer, the polyester elastomer constituting the core uses two types of polyester block copolymers (polyester block copolymer (A1) and polyester block copolymer (A2)). It is preferable from the viewpoint of improving the flame retardancy by improving the dispersibility of the flame retardant and improving the extensibility and heat shrinkability of the filament.

The polyester block copolymer (A1) is, for example, a high-melting point crystalline segment (H1) containing crystalline aromatic polyester as the main structural unit, and an aliphatic polyether unit and/or an aliphatic polyester as the main structural unit. A low melting point polymer segment (L1) is used as a constituent.

In the polyester block copolymer (A1), the high melting point crystalline segment (H1) may be composed of one type selected from the acid component and one or more types selected from the diol component. The high-melting point crystalline segment (H1) is, for example, a polybutylene terephthalate unit derived from terephthalic acid or dimethyl terephthalate and 1,4-butanediol.

The low melting point polymer segment (L1) may be selected from the above aliphatic polyethers and/or aliphatic polyesters.

The blending ratio of the high melting point crystalline segment (H1) and the low melting point polymer segment (L1) in the polyester block copolymer (A1) is 50 to 95% by mass for the high melting point crystalline segment (H1), and the low melting point crystalline segment (H1) is 50 to 95% by mass. It is preferable that the polymer segment (L1) is 5 to 50% by mass, the high melting point crystalline segment (H1) is 65 to 95% by mass, and the low melting point polymer segment (L1) is more preferably 5 to 35% by mass. , it is more preferable that the high melting point crystalline segment (H1) is 80 to 95 mass% and the low melting point polymer segment (L1) is 5 to 20 mass%. When the mixing ratio of the high-melting point crystalline segment (H1) and the low-melting point polymer segment (L1) is within the above range, the resulting fabric has an excellent balance of heat resistance, durability, and processability.

The melting point of the polyester block copolymer (A1) is preferably 200°C to 225°C, and more preferably 210°C to 225°C. When the melting point of the polyester block copolymer (A1) is within the above range, the resulting polyester elastomer has sufficient rigidity and heat resistance, and is also excellent in sag resistance.

The polyester block copolymer (A2) consists of a high-melting point crystalline segment (H2) containing crystalline aromatic polyester as the main structural unit, and a low-melting point polymer segment containing an aliphatic polyether unit and/or aliphatic polyester as the main structural unit. (L2) is used as a constituent.

In the polyester block copolymer (A2), the high melting point crystalline segment (H2) may be composed of two or more types selected from the above acid components and one or more types selected from the above diol components. For example, the high melting point crystalline segment (H2) includes a combination of terephthalic acid and isophthalic acid, a combination of terephthalic acid and dodecanedioic acid, and a combination of terephthalic acid and dimer acid.

By using the polyester block copolymer (A2) using two or more types of acid components, the resulting polyester elastomer can improve the dispersibility of the flame retardant and suppress aggregation of the flame retardant. As a result, polyester elastomers are prone to improved flame retardancy. Additionally, polyester elastomer can improve the extensibility or heat shrinkability of filament.

The high melting point crystalline segment (H2) consists of polybutylene terephthalate units derived from terephthalic acid and/or dimethyl isophthalate, and polybutylene isophthalate units derived from isophthalic acid and/or dimethyl isophthalate and 1,4-butanediol. It is desirable to consist of

The low melting point polymer segment (L2) may be selected from the above aliphatic polyethers and/or aliphatic polyesters.

The mixing ratio of the high melting point crystalline segment (H2) and the low melting point polymer segment (L2) in the polyester block copolymer (A2) is 40 to 90% by mass for the high melting point crystalline segment (H2), and the low melting point crystalline segment (H2) is 40 to 90% by mass. It is preferable that the polymer segment (L2) is 10 to 60% by mass, the high melting point crystalline segment (H2) is 45 to 85% by mass, and the low melting point polymer segment (L2) is more preferably 15 to 55% by mass. , it is more preferable that the high melting point crystalline segment (H2) is 70 to 85 mass% and the low melting point polymer segment (L2) is 15 to 30 mass%.

The melting point of the polyester block copolymer (A2) is preferably 120°C to 170°C, and more preferably 130°C to 165°C. Since the melting point of the polyester block copolymer (A2) is within the above range, the polyester block copolymer (A2) contributes to improving the dispersibility of flame retardants and the like when used in combination with the polyester block copolymer (A1). As a result, the resulting fabric has excellent abrasion resistance, toughness, flame retardancy, and appearance without impairing heat shrinkability.

In the polyester elastomer of the present embodiment, the blending amount (parts by mass) of the polyester block copolymer (A1) and the polyester block copolymer (A2) is 50 to 99 parts by mass of the polyester block copolymer (A1), and 50 to 99 parts by mass of the polyester block copolymer (A1). It is preferably 1 to 50 parts by mass of the block copolymer (A2), more preferably 60 to 95 parts by mass of the polyester block copolymer (A1), and 5 to 40 parts by mass of the polyester block copolymer (A2). More preferably, it is 70 to 95 parts by mass of the copolymer (A1) and 5 to 30 parts by mass of the polyester block copolymer (A2). When the blending amount (mass parts) of the polyester block copolymer (A1) and the polyester block copolymer (A2) is within the above range, the resulting polyester elastomer has excellent sag resistance and the dispersibility of the flame retardant is improved, thereby improving toughness. It has excellent flame retardancy.

Polyester block copolymer (A1) and polyester block copolymer (A2) can be produced by known methods. For example, polyester block copolymer (A1) and polyester block copolymer (A2) are prepared by mixing a lower alcohol diester of dicarboxylic acid, an excess amount of low molecular weight glycol, and a low melting point polymer segment component in the presence of a catalyst. It can be produced by carrying out a transesterification reaction and polycondensing the resulting reaction product, or by carrying out an esterification reaction between dicarboxylic acid and an excess amount of glycol and a low melting point polymer segment component in the presence of a catalyst and polycondensing the resulting reaction product. .

In addition, the polyester elastomer of the present embodiment may contain antioxidants (phosphonite compounds, phosphorous acid compounds, hypophosphorous acid compounds, hindered phenol-based compounds, thioether-based compounds, etc.) and ultraviolet absorbers (benzotriazole-based, benzotriazole-based compounds) as needed. Phenone-based, etc.), light stabilizers (HALS: hindered amine-based compounds, etc.), antistatic agents (polyether esteramide, etc.), lubricants (stearyl alcohol, stearic acid metal salt, stearic acid amide, stearic acid glyceride, etc.), dyes ( organic dyes such as nigrosine), pigments (carbon black, titanium dioxide, etc.), plasticizers (phthalic acid, adipic acid, trimellitic acid, etc.), mold release agents (paraffin wax, saturated fatty acid ester, unsaturated fatty acid ester, etc.) , additives such as transesterification inhibitors may be added, or other thermoplastic resins such as styrene-based resins, olefin-based resins, and polyvinyl chloride-based resins may be added.

In addition to the organic phosphorus-containing compounds exemplified as flame retardants, phosphorus-containing compounds include hydrates of metal hypophosphorous acid salts. By using a hydrate of metal hypophosphite, the polyester elastomer is easy to suppress oxidation deterioration and is also easy to improve the surface appearance and color tone.

(No. 1 flame retardant)

The first flame retardant is a flame retardant contained in the core. The first flame retardant preferably contains at least one selected from the group consisting of organic phosphoric acid ester compounds, metal phosphinic acid salts, and triazine skeleton-containing compounds. As a result, the resulting fabric is less prone to scum during the spinning process or knitting process, and is more stable and exhibits excellent appearance and flame retardancy.

Organic phosphoric acid ester compounds include, for example, resorcinol phosphates, tetrakis (2,6-dimethylphenyl) 1,3-phenylenebisphosphate, resorcinolbis (diphenyl phosphate), and hydroquinone phosphates. , hydroquinone bis(diphenyl phosphate), biphenol phosphates such as biphenol bis(diphenyl phosphate), and bisphenol phosphates such as bisphenol-A bis(diphenyl phosphate).

Organic phosphate ester compounds exhibit a lower melting point than general thermoplastic polyester elastomers and have good compatibility with polyester elastomers. Therefore, the organic phosphoric acid ester compound has excellent dispersibility during melt kneading. In addition, the organic phosphoric acid ester compound can improve the flame retardancy of the polyester elastomer and suppress the decline in mechanical strength characteristics.

Additionally, as the organic phosphoric acid ester compound, an arylspirodiphosphinate condensed with a polyhydric alcohol such as pentaerythritol is also preferably used.

Furthermore, among organic phosphoric acid ester compounds, diphosphinate compounds having a spiro-type ring condensation structure exhibit a high melting point, are easier to improve in dispersibility in polyester elastomers, and also have high heat resistance. Therefore, a diphosphinate compound having a spiro-type ring condensation structure is more preferably used because it can suppress bleed-out during processing.

The melting point of arylspirodiphosphinate is preferably 100 to 300°C. When the melting point is within the above range, the arylspirodiphosphinate is difficult to bleed out during melt processing and is excellent in dispersibility and processability during melt processing. As a result, the toughness, sag resistance, and surface appearance of the resulting filament or molded product are likely to be improved.

The acid value of arylspirodiphosphinate is preferably 1.0 mgKOH/g or less, and more preferably 0.5 mgKOH/g or less. When the acid value is within the above range, the resulting polyester elastomer has excellent flame retardancy and color. In addition, the obtained filament using the polyester elastomer is prone to suppressing deterioration in heat aging resistance and hydrolysis resistance.

Arylspirodiphosphinate is, for example, a pentaerythritol diphosphinate compound. Specifically, the pentaerythritol diphosphinate compound is 2,4,8,10-tetraoxa-3,9-diphosphaspiro[5.5]undecane, 3,9-dibenzyl-3,9-dioxide, 2, 4,8,10-tetraoxa-3,9-diphosphaspiro[5.5]undecane, 3,9-diα-methylbenzyl-3,9-dioxide, 2,4,8,10-tetraoxa-3 ,9-diphosphaspiro[5.5]undecane, 3,9-di(2-phenylethyl)-3,9-dioxide, 2,4,8,10-tetraoxa-3,9-diphosphaspiro[5 ,5]undecane, 3,9-bis(diphenylmethyl)-3,9-dioxide, etc.

The content of the organic phosphate ester compound is preferably 1% by mass or more, and more preferably 10% by mass or more relative to the entire core. Moreover, the content of the organic phosphoric acid ester compound is preferably 30% by mass or less, and more preferably 20% by mass or less, relative to the entire core. When the content of the organic phosphoric acid ester compound is within the above range, the resulting fabric does not impair heat shrinkability and has excellent toughness, flame retardancy, and appearance.

Phosphinic acid metal salts are a group of compounds represented by the general formula R ¹ R ² P(=O)OM or [{OP(=O)R ¹ }-R ³ -{P(=O)R ² -O}]M am. R ¹ and R ² may be the same or different organic groups, and R ³ is methylene, ethylene, n-propylene, isopropylene, n-butylene, t-butylene, phenylene, or naphthylene, and the aromatic ring phase It may have several substituents. M is aluminum, zinc, calcium, magnesium.

Specific examples of metal phosphinic acid salts (also referred to as metal phosphinate compounds) include metal salts of phosphinic acid substituted with an aliphatic hydrocarbon group, such as metal salts of diethyl phosphinate and metal salts of methyl ethyl phosphinate, and aluminum phosphinic acid salts. (aluminum diethylphosphinate) or zinc phosphinate (zinc diethylphosphinate) is preferable. Among these, the metal phosphinic acid salt is more preferably an aluminum phosphinic acid salt because it can greatly improve the flame retardancy of the polyester elastomer and suppress bleed-out during processing.

The content of the metal phosphinic acid salt is preferably 1 mass% or more, and more preferably 10 mass% or more, based on the entire core. Additionally, the content of the metal phosphinic acid salt is preferably 30% by mass or less, and more preferably 20% by mass or less, based on the entire core. When the content of the metal phosphinic acid salt is within the above range, the polyester elastomer obtained has excellent flame retardancy and excellent processability.

On the other hand, the organic phosphorus-containing compound and the phosphinic acid metal salt are previously melt-kneaded with the above-described polyester elastomer in a specific range to produce a flame-retardant masterbatch, and the flame-retardant masterbatch is further melt-kneaded with the polyester elastomer to produce the organic phosphorus-containing compound. It is possible to obtain a flame-retardant polyester elastomer resin composition and a flame-retardant polyester elastomer filament that can suppress agglomeration, suppress deterioration of mechanical properties, and have excellent flame retardancy, surface appearance, surface smoothness, toughness and sag resistance.

The thermoplastic resin used when producing the masterbatch containing the organic phosphorus-containing compound may be the polyester elastomer described above, and may be polyethylene terephthalate (PET), polybutylene terephthalate (PBT), polyethylene naphthalate (PEN), or polybutyl. Thermoplastic polyester resins such as lennaphthalate (PBN) may be used.

Additionally, the organic phosphorus-containing compound may be used together with the polyester elastomer when molding the masterbatch.

In this embodiment, the composition ratio of the thermoplastic polyester elastomer and the organic phosphorus-containing compound contained in the masterbatch is set to 100% by mass of the polyester elastomer because it suppresses a decrease in the processability of the resulting polyester elastomer and provides excellent flame retardancy. It is preferable to melt-knead the organic phosphorus-containing compound in the range of 10 to 100 parts by mass, and to suppress agglomeration of the organic phosphorus-containing compound and improve surface appearance and surface smoothness, melt-knead in the range of 20 to 70 parts by mass. It is more desirable to do so.

Triazine skeleton-containing compounds include, for example, melamine cyanurate, melamine, cyanuric acid, isocyanuric acid, triazine derivatives, and isocyanurate derivatives, and melamine cyanurate is preferred.

Melamine cyanurate is preferably in the form of particles (powder). In addition, melamine cyanurate may be untreated or may be surface treated with a coupling agent (especially a silane coupling agent).

In addition to this, the triazine skeleton-containing compound may also be preferably a group of compounds having a triazine ring in the hindered amine structure that is generally used as a radical supplement. By adding a triazine ring-containing hindered amine compound to the polyester elastomer, not only does it bring about a general weather resistance improvement effect, but also a flame retardancy improvement effect is obtained.

This is because the combustion suppression effect can be obtained through the synergistic effect of the triazine skeleton-containing hindered amine compound contributing as a radical scavenger to the chain reaction through active radicals in the combustion process of the polyester elastomer.

By having a hindered amine structure, the triazine skeleton-containing compound can suppress aggregation of triazine rings, and the dispersibility of the triazine skeleton-containing compound can be improved. As a result, the polyester elastomer obtained has improved surface appearance, surface smoothness, toughness and sag resistance.

The hindered amine compound is preferably a triazine ring-containing N-alkoxy hindered amine compound. Compared to N-H type hindered amine compounds and N-R type hindered amine compounds, triazine ring-containing N-alkoxy hindered amine compounds generate nitroxide radicals with a high radical capturing ability during combustion, and alkyl substituted hindered amine compounds In comparison, flame retardancy is more likely to be improved.

The triazine ring-containing N-alkoxy hindered amine compound is specifically 1,5,8,12-tetrakis [2,4-bis(N-butyl-N-(2,2,6,6-tetramethyl- 4-piperidyl) amino) -1,3,5-triazin-6-yl] -1,5,8,12-tetraazadodecane, 1,5,8,12-tetrakis [2,4 -bis(N-butyl-N-(2,2,6,6-tetramethyl-4-piperidyl)amino)-1,3,5-triazin-6-yl]-1,12-dimethyl- 1,5,8,12-tetraazadodecane, etc., and examples of commercially available products include Flamestab NOR116FF manufactured by BASF Japan Co., Ltd.

The content of the triazine skeleton-containing compound is preferably 1 mass% or more, and more preferably 3 mass% or more, based on the entire core. Furthermore, the content of the triazine skeleton-containing compound is preferably 30% by mass or less, and more preferably 10% by mass or less, based on the entire core. When the content of the triazine skeleton-containing compound is within the above range, the resulting polyester elastomer has excellent flame retardancy and is also excellent in toughness, sag resistance, and surface appearance.

Returning to the description of the entire first flame retardant, the total amount of the organic phosphate ester compound, phosphinic acid metal salt, and triazine skeleton-containing compound is preferably 1% by mass or more relative to the core, and more preferably 10% by mass or more. Additionally, the total amount of the organic phosphoric acid ester compound, metal phosphinic acid salt, and triazine skeleton-containing compound is preferably 30% by mass or less, and more preferably 20% by mass or less, based on the core portion. When the total amount of the organic phosphoric acid ester compound, metal phosphinic acid salt, and triazine skeleton-containing compound is within the above range, the resulting fabric is less likely to form scum during the spinning process or knitting process, and is more stable and exhibits excellent flame retardancy.

Returning to the description of the entire core portion, the content of the core portion may be 60 volume% or more, and is preferably 70 volume% or more relative to the core-sheath composite fiber. Additionally, the content of the core portion may be 90 volume% or less relative to the core-sheath composite fiber, and is more preferably 80 volume% or less. By setting the core content to 60% by volume or more, the resulting fabric does not impair heat shrinkage and exhibits better seating comfort. On the other hand, by setting the core content to 90% by volume or less, the resulting fabric is less prone to scum during the spinning process or knitting process, and is more stable and exhibits excellent flame retardancy.

(beginning)

The sheath portion contains polyester excluding the polyester elastomer included in the core portion described above. Additionally, the sheath preferably includes a second flame retardant.

(Polyester excluding polyester elastomer included in the core)

Polyester other than the polyester elastomer contained in the core is not particularly limited. For example, polyesters other than the polyester elastomer included in the core include polyethylene terephthalate (PET), polybutylene terephthalate (PBT), polyethylene naphthalate (PEN), and polybutylene naphthalate (PBN). Among these, the polyester excluding the polyester elastomer contained in the core portion is preferably PET from the viewpoint of productivity.

(second flame retardant)

The sheath preferably contains a second flame retardant. The second flame retardant is not particularly limited. For example, the second flame retardant preferably contains at least one of an arylphosphinic acid compound or an alkylphosphinic acid compound. Moreover, it is more preferable that the second flame retardant is one in which at least one of an arylphosphinic acid compound or an alkylphosphinic acid compound is copolymerized with the polyester. By containing at least one of an arylphosphinic acid compound or an alkylphosphinic acid compound as the second flame retardant, the resulting fabric is less prone to scum during the spinning process or knitting process, and is more stable and exhibits excellent appearance and flame retardancy. When the second flame retardant is an arylphosphinic acid compound or an alkylphosphinic acid compound, these are added to the polymerization system before polycondensation after transesterification or in the initial stage of the polycondensation reaction, and are copolymerized in the polyester main chain. desirable.

The arylphosphinic acid compound is not particularly limited. For example, arylphosphinic acid compounds include 2-carboxyethyl(phenyl)phosphinic acid, 2-carboxyethyl(naphthyl)phosphine, and 2-carboxyethyl(toluyl)phosphinic acid. Among these, the arylphosphinic acid compound is preferably 2-carboxyethyl(phenyl)phosphinic acid.

The alkylphosphinic acid compound is not particularly limited. For example, alkylphosphinic acid compounds include 2-carboxyethylmethylphosphinic acid, 2-carboxyethyl-tert-butylphosphinic acid, etc. Among these, the alkylphosphinic acid compound is preferably 2-carboxyethylmethylphosphinic acid.

The content of the second flame retardant is preferably 0.3% by mass or more, more preferably 0.5% by mass or more, and even more preferably 0.6% by mass or more in terms of elemental phosphorus, relative to the sheath. Additionally, the content of the second flame retardant is preferably 1.1% by mass or less, more preferably 1.0% by mass or less, and even more preferably 0.9% by mass or less in terms of elemental phosphorus, relative to the sheath. When the content of the second flame retardant is within the above range, the resulting fabric is less prone to scum during the spinning process, knitting process, etc., and is more stable and exhibits excellent flame retardancy.

Returning to the description of the entire sheath portion, the content of the sheath portion may be 10 volume% or more relative to the core-sheath composite fiber, and is preferably 20 volume% or more. Additionally, the content of the sheath may be 40 volume% or less relative to the core-sheath composite fiber, and is more preferably 30 volume% or less. When the content of the sheath is 10% by volume or more, the resulting fabric is less likely to form scum during the spinning process or knitting process, and is more stable and exhibits excellent flame retardancy. On the other hand, when the sheath content is 40% by volume or less, the resulting fabric can be prevented from being damaged in heat shrinkability.

Returning to the description of the entire fabric, the monofilament content in the fabric may be 50% by mass or more, preferably 60% by mass or more, and more preferably 70% by mass or more. By setting the monofilament content to 50% by mass or more, the resulting fabric exhibits an appropriate amount of deflection when attached to a frame member.

The fineness of the monofilament is preferably 300 dtex or more, and more preferably 500 dtex or more. Additionally, the fineness of the monofilament is preferably 3000 dtex or less, and more preferably 2000 dtex or less. Since the fineness of the monofilament is 300 dtex or more, the fabric has excellent strength. On the other hand, when the fineness of the monofilament is 3000 dtex or less, the monofilament has excellent process passability. Additionally, the fineness of monofilament can be calculated based on JIS L 1018 (2010) 8.7.1.

The dry heat shrinkage rate of monofilament is preferably 5.0% or more, more preferably 10.0% or more, and even more preferably 20.0% or more. In addition, the dry heat shrinkage rate of monofilament is preferably 50.0% or less, more preferably 45.0% or less, and even more preferably 40.0 or less. When the dry heat shrinkage rate of the monofilament is within the above range, the resulting fabric shrinks appropriately when heated and is easily attached to the frame member. Additionally, the fabric can be easily adjusted to have an appropriate amount of bending when attached to the frame member. In addition, the dry heat shrinkage rate of the fiber can be adjusted by the base polymer constituting the fiber, the core/sheath ratio, the type of flame retardant, the amount of flame retardant added, spinning conditions, etc. In addition, monofilament, which is a core-sheath composite fiber containing a polyester elastomer with a fineness of 300 to 3000 dtex with a dry heat shrinkage rate adjusted to 5.0 to 50.0%, can be preferably used in the fabric of the present invention. Additionally, the dry heat shrinkage rate can be measured based on JIS L 1013 (8.18.2) (2010) Method B (filament shrinkage rate).

The melting point of the core-sheath composite fiber constituting the monofilament is not particularly limited. For example, the melting point of the core-sheath composite fiber is preferably 200°C or higher, and more preferably 225°C or higher. Additionally, the melting point of the core-sheath composite fiber is preferably 280°C or lower, and more preferably 260°C or lower. When the melting point of the core-sheath composite fiber is within the above range, the durability of the resulting fabric, such as abrasion resistance, is further improved.

Additionally, the melting point of the core portion is not particularly limited. For example, the melting point of the core portion is preferably 200°C or higher, and more preferably 210°C or higher. Additionally, the melting point of the core portion is preferably 230°C or lower, and more preferably 220°C or lower. On the other hand, the melting point of the initial part is not particularly limited. For example, the melting point of the sheath is preferably 225°C or higher, and more preferably 235°C or higher. Additionally, the melting point of the sheath is preferably 280°C or lower, and more preferably 260°C or lower. When the melting points of the core and sheath are within the above range, the resulting fabric has improved durability such as abrasion resistance.

The manufacturing method of monofilament, which is a core-sheath composite fiber, is not particularly limited. For example, monofilament can be manufactured by a core-sheath composite spinning method using conventionally known coextrusion equipment. According to the core-sheath composite spinning method, monofilament has high productivity and can be produced at low cost.

More specifically, the first flame retardant and polyester elastomer constituting the core portion, and the polyester constituting the sheath portion are melted in each extruder, and then each is metered with a gear pump and introduced into the composite pack. The two types of polymers that make up the core and sheath introduced into the composite pack are filtered through a metal non-woven filter or metal mesh within the pack, then introduced into the composite spinneret and discharged in a form where the core is surrounded by the sheath. .

In addition, when imparting functions such as doping, imparting light resistance, and imparting antibacterial properties to the monofilament, a master chip containing a large amount of the desired pigment, light resistance agent, antibacterial agent, etc. is manufactured, and the first flame retardant and the first flame retardant constituting the core portion are prepared. Spinning can be performed by mixing the polyester elastomer and/or the polyester constituting the sheath in the required amount.

The molten monofilament discharged from the composite spinneret is cooled, stretched, and heat set according to a conventional method, so that monofilament, which is a core-sheath composite fiber, can be efficiently produced.

Additionally, the fabric may contain fibers other than the monofilament. For example, fibers other than monofilament are synthetic fibers that are multifilament. Among these, preferred fibers include multifilaments of polyester fibers and multifilaments of polyamide fibers. The multifilament may be a processed yarn that has undergone processing such as false twisting. Among these, it is preferable that the fiber other than monofilament is false twisted PET in order to improve the touch and feel of the fabric and from the viewpoint of productivity. The content of fibers other than these monofilaments is less than 50% by mass, and is preferably 40% by mass or less.

The fabric may be knitted or woven. The fabric of this embodiment is preferably a plain fabric because it has excellent elasticity, provides better seating comfort, improves breathability, and provides abundant variations in pattern expression.

It is preferable that the piece density in at least one of the warp direction and the weft direction is 10 pieces/25.4 mm or more, and preferably 15 pieces/25.4 mm or more. Moreover, the piece density is preferably 50 pieces/25.4 mm or less, and more preferably 40 pieces/25.4 mm or less. When the piece density is within the above range, the resulting fabric is likely to have an appropriate amount of deflection and strength when attached to a frame member. As a result, the resulting fabric material exhibits better seating comfort and breathability.

The fabric preferably has a deflection of 20 mm or more when a load of 400 N is applied to the center, and more preferably 30 mm or more. Additionally, the amount of deflection is preferably 60 mm or less, and more preferably 50 mm or less. When the amount of deflection is within the above range, the amount of deflection of the fabric body obtained using the fabric is within an appropriate range when a load is applied to the support surface that supports the user (for example, when the fabric body is the back or seat of a seating seat). It can be. As a result, the resulting fabric body has excellent seating comfort. Additionally, the resulting fabric can maintain appropriate elasticity. Additionally, the center of the fabric refers to the center of the planar shape of the fabric. In other words, for example, if the shape of the fabric is a polygon, the center of the polygon becomes the center of the fabric.

Additionally, the air permeability of the fabric is preferably 5 cm3/cm2/sec or more, and more preferably 20 cm3/cm2/sec or more. Additionally, the air permeability of the fabric is preferably 300 cm3/cm2/sec or less, and more preferably 180 cm3/cm2/sec or less. When the air permeability of the fabric is within the above range, the resulting fabric body has a reduced feeling of sweating when the user uses it, and can sufficiently support the body. In this embodiment, air permeability can be measured based on JIS L 1096 (8.27.1) (2010) A method (Fraser method).

The fabric of the present embodiment contains a first flame retardant in the core portion of the core-sheath composite fibers constituting the monofilament. The first flame retardant contained in this core portion is unlikely to generate scum in processes such as a spinning process or a piece process. As a result, the resulting fabric not only exhibits an excellent appearance but also exhibits excellent flame retardancy. For example, in terms of the combustibility of the fabric in FMVSS 302 (horizontal method), it is desirable that the combustibility speed is 0 mm/min. This indicates that the letter is written in front of the A symbol. In FMVSS 302 (horizontal method), the combustion speed is 0 mm/min, so it has excellent flame retardancy in that it exhibits self-extinguishing properties. The combustibility of the fabric is more preferably determined by the 20 mm vertical combustion test (UL94V test) at a grade of V-0. In the 20 mm vertical combustion test (UL94V test), the judgment grade is V-0, which has better flame retardancy.

(no frame)

The frame member is not particularly limited. The frame member is a member that has the strength to withstand the tension of the fabric when the fabric is fixed with tension applied in at least one direction. Specifically, the frame members are metals such as iron, aluminum, and titanium, carbon, wood, and plastic. Among these, the frame member is preferably made of metal or carbon in terms of high strength, and more preferably made of carbon in terms of weight reduction.

Returning to the overall description of the fabric body, the method of manufacturing the fabric body by attaching the fabric to the frame member is not particularly limited. Figure 1 is a schematic diagram for explaining a method of attaching a frame member to a fabric. Figure 2 is a schematic diagram of a fabric body.

As shown in FIG. 1, the fabric 1 is a bag-like letter processed into a three-dimensional shape so that the frame member 2 can be inserted therein. It is possible to knit letters using a weft knitting machine. The weft knitting organization is not particularly limited. For example, the weft knitting tissue is a fabrication fabric, a garter fabrication, a smooth fabric, a rib fabric, etc. The fabric 1 is formed with an opening 1a for inserting a frame member. From the opening 1a, as shown in FIG. 1, for example, a frame member (the first frame member 2a and the second frame member 2b) decomposed into two parts is inserted, and the fabric 1 ) are assembled to form an approximately rectangular frame member 2. Next, for example, by heat treatment, the fabric 1 is heat-shrinked and comes into close contact with the frame member 2, as shown in FIG. 2. As a result, the fabric body 3 can be formed in a non-sewn, non-adhesive manner. The fabric body formed in a non-sewn and non-adhesive manner can be deployed in a variety of applications where it is desirable to form a three-dimensional fabric surface while being non-sewn and non-adhesive.

The use of the fabric body of this embodiment is not particularly limited. For example, the fabric material maintains excellent flame retardancy and also exhibits excellent seating comfort and breathability, so it is suitable for various sheets. More specifically, the fabric body is suitable as a seating surface or backrest for office chairs, car seats, railway car seats, etc.

Above, one embodiment of the present invention has been described. The present invention is not particularly limited to the above embodiments. In addition, the above-described embodiment mainly explains the invention having the following configuration.

(1) Contains 50% by mass or more of monofilament, wherein the monofilament is a core-sheath composite fiber having a core portion and a sheath portion, and the core portion contains 60 to 90% by volume relative to the core-sheath composite fiber, and further includes a first flame retardant and poly A fabric comprising an ester elastomer, wherein the sheath portion contains 10 to 40% by volume relative to the core-sheath composite fiber, and is made of polyester excluding the polyester elastomer of the core portion.

According to this configuration, the first flame retardant contained in the core portion is unlikely to appear as scum during the spinning process or the knitting process. As a result, the fabric has an excellent appearance and is easy to maintain excellent flame retardancy. Additionally, the fabric exhibits excellent seating comfort and breathability.

(2) The fabric is a straight fabric, and the fabric has a piece density of 10 to 50 pieces/25.4 mm in at least one of the warp direction and the weft direction, and the fineness of the monofilament is 300 to 3000 dtex, (1) The fabric described in .

According to this configuration, the fabric exhibits better seating comfort and breathability.

(3) The first flame retardant contains at least one selected from the group consisting of organic phosphoric acid ester compounds, phosphinic acid metal salts, and triazine skeleton-containing compounds, and is contained in an amount of 1 to 30% by mass relative to the core, (1) Or the fabric described in (2).

According to this configuration, the fabric is less prone to scum during the spinning process, knitting process, etc., and is more stable and exhibits excellent flame retardancy.

(4) The sheath contains a second flame retardant, and the second flame retardant contains at least one of an arylphosphinic acid compound or an alkylphosphinic acid compound, and is contained in an amount of 0.3 to 1.1% by mass in terms of elemental phosphorus relative to the sheath. , the fabric according to any one of (1) to (3).

According to this configuration, the fabric is less prone to scum during the spinning process, knitting process, etc., and is more stable and exhibits excellent flame retardancy.

(5) A fabric body comprising the fabric according to any one of (1) to (4) and a frame member.

According to this configuration, the fabric body has an excellent appearance and is easy to maintain excellent flame retardancy. Additionally, the fabric material exhibits excellent seating comfort and breathability.

(6) The fabric body according to (5), wherein the fabric is formed without sewing and without adhesiveness.

According to this configuration, the fabric is non-sewn and non-adhesive and can be deployed for various applications where formation of a three-dimensional fabric surface is desirable.

(7) A sheet using the fabric according to (5) or (6).

According to this configuration, the sheet is likely to maintain excellent flame retardancy. Additionally, the sheet exhibits excellent seating comfort and breathability.

Example

Hereinafter, the present invention will be described in detail based on examples. The present invention is not limited to these examples. In addition, the performance in the examples was measured by the following method.

[measurement method]

(1) Volume ratio of core and sheath of core-sheath composite fiber

Collect monofilament from the fabric, cut it in the direction perpendicular to the fiber axis, observe the cut surface obtained using a digital microscope (VHX-6000, manufactured by Keyence), and measure the core and sheath using the length measurement tool of the digital microscope. The diameter was measured, and the volume percentage of the core and the volume percentage of the sheath were obtained from the cross-sectional area of the monofilament and the cross-sectional areas of the core and sheath using the area measurement tool of the digital microscope. The number of observed samples was set to 10 and obtained from the average value. Additionally, decimal places are rounded off.

(2) Elemental amount of phosphorus

7 g of the sample was melted and molded into a plate shape, and the intensity was measured by fluorescence X-ray analysis (Fluorescence It was set as element content (mass %).

(3) Melting temperature of the core and sheath of the core-sheath composite fiber

Using a differential scanning calorimeter type DSC-7 manufactured by PerkinElmer, a 10 mg monofilament sample collected from the fabric was measured at a temperature increase rate of 10°C/min from 30°C to 280°C, and the extreme value of the obtained melting endothermic curve was given. The temperature was taken as each melting point.

(4) Fineness of monofilament

Based on JIS L 1018 (2010) 8.7.1, 25 monofilaments collected from the fabric were unwound, their length (mm) and mass (mg) were measured, and the fineness (dtex) of the monofilament was calculated using the following equation. .

T=W/L×100

Here,

T: Fineness (dtex)

W: Total mass of 25 filaments (mg)

L: Total length of 25 filaments (mm)

(5) Dry heat shrinkage of monofilament

Measured according to JIS L 1013 (8.18.2) (2010) method B (filament shrinkage rate). An initial load was applied to the sample, an exact distance of 500 mm was measured, two points were marked, the initial load was removed, and the sample was hung in a dryer set at 185°C for 15 minutes before being taken out. After cooling to room temperature, apply the initial load again, measure the length (mm) between the two points, and calculate the dry heat shrinkage (%) using the following equation ((500 - length between the two points after heat treatment)/500 × 100), The average value of 5 times was calculated. Here, the initial load was set according to the fineness of the sample in accordance with JIS L 1013 (8.5.1).

(6) Radioactivity

Continuous spinning is performed for 12 hours, and the 4th item (filter clogging, occurrence of scum, occurrence of thread breakage, number of occurrences of neps) is judged based on the following criteria. As a comprehensive evaluation of the 4 items, if all 4 items are ○, " ○”, and if any of the 4 items had ×, it was evaluated as “×” and level 2.

A. Clogged filter

○: There was no clogging of the filter, the discharge state was stable, and there was no hindrance to radiation.

×: The filter became clogged, the discharge state became unstable, and discharge became impossible due to the increase in filtration pressure.

B. Occurrence of scum

○: There was no occurrence of scum during the spinning process.

×: Generation of scum was confirmed during the spinning process.

C. Thread breakage

○: The occurrence of thread breakage occurred once or less.

×: Thread breakage occurred twice or more.

D. Number of occurrences of Nepsa

○: The occurrence of neps exceeding +20% of the average monofilament diameter was less than 10 times/ton.

×: The occurrence of nepsa exceeding +20% of the average monofilament diameter was 10 times/ton or more.

In addition, the number of occurrences of neps was expressed as the total weight of the extruded polymer (kg) / 1000 kg × the number of occurrences of neps.

(7) Ventilation

Measured in accordance with JIS L 1096 (8.27.1) (2010) A method (Fraser method). Test pieces of 20 cm When attaching the test piece, the test piece was placed on a cylinder, and a load of about 98 N (10 kgf) was applied evenly so as not to block the intake portion on the test piece to prevent air leakage from the attachment portion of the test piece. After attaching the test piece, adjust the suction fan using a rheostat so that the inclined barometer indicates a pressure of 125 Pa. From the pressure indicated by the vertical barometer at that time and the type of air hole used, the table attached to the tester is used. The amount of air passing through the test piece was determined, and the average value for five test pieces was calculated.

(8) Bending amount when 400N load is applied

For the fabric body having the fabric extended to the frame member, the amount of deflection when a load of 400 N was applied was measured using a static load deflection tester for sheets (FGS-TV, manufactured by Nippon Densan Shimpo Co., Ltd.). Specifically, a fabric body was obtained by stretching the fabric over a frame member made of metal. Next, the fabric body is installed on a fixing jig with a height of 30 cm, and an initial load of 5 N is applied by a horizontally elongated pressure plate with a width of 250 mm × 300 mm so that the center of the pressure plate overlaps the center of the fabric, At this time, the center of load of the pressure plate was taken as the origin. First, as preliminary compression, a load of up to 900 N is applied at a speed of 50 mm/min, then unloaded at a speed of 50 mm/min, and after leaving for 1 minute, a load of up to 900 N is similarly applied and unloaded at a speed of 50 mm/min. was performed, and the amount of deflection at the origin when each load was applied was measured. The “bending amount when a load of 400N is applied” herein refers to the amount of bending at the origin when a load of 400N is applied to the fabric. Here, there are no particular restrictions on the directionality of the fabric when fixing it on the frame fixing jig, and it may be in either the vertical or horizontal direction.

(9) Combustibility (horizontal method)

Test pieces with a length of 250 mm and a width of 120 mm were randomly collected from the fabric, three in each of the vertical and horizontal directions. Next, evaluation was performed based on FMVSS 302 (horizontal method). Install the test piece horizontally with a dedicated jig in between, and apply a 38 mm flame to the end for 15 seconds. The combustion time (seconds) until it reaches 254 mm between the A mark and the B mark is measured as the B mark. In cases where it did not reach, the combustion distance (mm) and the combustion time (seconds) were measured. In addition, when the A mark was not reached, the combustion distance was recorded as 0 mm and the combustion time was recorded as 0 seconds. Then, from the measured combustion time and combustion distance, the combustion rate was calculated for each of the vertical and horizontal directions of the fabric using Equation 1 below. Here, “combustibility (horizontal method)” refers to the average value of the combustion speed of three test pieces in each of the vertical and horizontal directions of the fabric.

Equation 1 Combustion speed (mm/min) = combustion distance (mm) / combustion time (seconds) × 60

(10) Flammability (UL94V)

Test pieces with a length of 125 mm and a width of 13 mm were randomly collected from the fabric, 5 each in the vertical and horizontal directions. Next, evaluation was conducted based on the 20 mm vertical combustion test (UL94V test) in the UL94 standard. Here, UL is a safety standard for electronic devices established and approved by Underwriters Laboratories Inc. in the United States, and UL94 is also a flame retardancy standard. After evaluation, the grade of flammability (UL94V) was determined according to established judgment criteria. Combustibility (flame retardancy) has three levels of judgment criteria: V-0, V-1, and V-2, and is ranked in decreasing order of V-0>V-1>V-2, with V-0 being level 3. It shows the best flame retardancy. In addition, V-0 was determined to satisfy the criteria for V-0 in all 10 sheets in the vertical and horizontal directions. In V-2, at least one out of a total of 10 sheets in both vertical and horizontal directions met the criteria for V-2.

(11) Comprehensive evaluation

Comprehensive evaluation of the obtained fabric was performed based on the following criteria.

◎: The amount of deflection of the fabric when a load of 400N is applied is in the range of 20 to 60 mm, the combustibility of the fabric (horizontal method) has a combustion speed of 0 mm/min, and the judgment grade of the combustibility of the fabric (UL94V) is V-0, The comprehensive evaluation of the radioactivity of the monofilament used in the fabric was ○.

○: When a load of 400N is applied to the fabric, the amount of deflection is in the range of 20 to 60 mm, the combustibility (horizontal method) of the fabric is at a combustion speed of 0 mm/min, and the judgment grade of the combustibility (UL94V) of the fabric is V-0. It was not satisfied and/or the comprehensive evaluation of the radioactivity of the monofilament used for the fabric was ×.

×: At least one of the following is satisfied: the amount of deflection of the fabric when a load of 400N is applied is less than 20 mm or more than 60 mm, and the combustibility (horizontal method) of the fabric exceeds 0 mm/min.

[Reference example]

(pellet)

The constituent materials were dry blended, melt-kneaded at a temperature setting of 240°C using a twin-screw extruder with a screw of 45 mm ϕ, discharged into strands, and then pelletized into 3 mm ϕ and 3 mm in length using a pelletizer. First, the manufacturing method of polyester elastomer is shown.

(Method for producing polyester elastomer (A1))

A polyester containing 80% by mass of a high-melting point crystalline segment (H1) whose main structural unit is a crystalline aromatic polyester, and 20% by mass of a low-melting point polymer segment (L1) whose main structural unit is an aliphatic polyether. Block copolymer (A1-1) was prepared. 58.0 parts of terephthalic acid, 36.7 parts of 1,4-butanediol, 15.0 parts of poly(oxytetramethylene) glycol with a number average molecular weight of about 1000, 0.04 parts of titanium tetrabutoxide, and 0.02 parts of mono-n-butyl-monohydroxytin oxide are added together into a helical form. It was poured into a reaction vessel equipped with a ribbon-shaped stirring blade, heated at 220 to 245°C for 3 hours, and an esterification reaction was performed while the reaction water was allowed to flow out of the system. 0.2 part of tetra-n-butyl titanate was additionally added to the reaction mixture, and 0.05 part of "Irganox" 1098 (a hindered phenolic antioxidant manufactured by Ciba Geig) was added, then the temperature was raised to 255°C, and then for 50 minutes. Over time, the pressure in the system was reduced to 27 Pa, and polymerization was performed for 1 hour and 50 minutes under those conditions. The obtained polymer was discharged into water in the form of a strand and cut into pellets. The melting point was 217°C.

(Method for producing polyester elastomer (A2))

80% by mass of a high-melting point crystalline segment (H2) containing crystalline aromatic polyester as the main structural unit and 20% by mass of a low-melting point polymer segment (L2) with aliphatic polyether as the main structural unit are used as components, and A polyester block copolymer (A2-1) in which the melting point crystalline segment (H2) is composed of two types of acid components and a diol component was produced. As two types of acid components, 45.0 parts of terephthalic acid and 20.0 parts of isophthalic acid, 41.6 parts of 1,4-butanediol and 18.5 parts of poly(oxytetramethylene) glycol with a number average molecular weight of about 1000, 0.04 parts of titanium tetrabutoxide and mono-n. 0.02 part of -butyl-monohydroxytin oxide was added to a reaction vessel equipped with a helical ribbon-type stirring blade, heated at 190 to 220°C for 3 hours, and an esterification reaction was performed while the reaction water was discharged to the outside of the system. 0.15 part of tetra-n-butyl titanate was further added to the reaction mixture, and 0.05 part of "Irganox" 1098 (a hindered phenolic antioxidant manufactured by Ciba Geigi) was added, then the temperature was raised to 245°C, and then for 50 minutes. The pressure in the system was reduced to 27 Pa, and polymerization was performed for 1 hour and 50 minutes under those conditions. The obtained polymer was discharged into water in the form of a strand and cut into pellets. The melting point was 164°C.

(Method for producing polyester (A3))

A slurry of 1,100 parts by weight of terephthalic acid and 480 parts by weight of ethylene glycol was supplied over 3 hours to an esterification reaction tank maintained at a temperature of 245°C where 1,950 parts by weight of bishydroxyethyl terephthalate was injected, and the water generated during the esterification reaction was The esterification reaction was performed while distilling it out of the reaction system. 1300 parts by weight of the oligomer after reaction was transferred to a polycondensation reaction tank. Next, a previously prepared slurry of 65 parts by weight of 2-carboxyethyl(phenyl)phosphinic acid and 150 parts by weight of ethylene glycol was added to the transferred oligomer 40 minutes before starting the polycondensation reaction, followed by diantimony trioxide. 500 ppm was added, and then the temperature of the reaction system was gradually raised from 250°C to 290°C. At the same time, ethylene glycol was distilled off and the pressure of the reaction system was reduced to 50 Pa. Additionally, a slurry of 2-carboxyethyl(phenyl)phosphinic acid and ethylene glycol was prepared 50 minutes before the start of addition of the slurry into the polycondensation reaction system. At the point when the predetermined stirrer torque is reached, nitrogen is introduced into the reaction system, the pressure is returned to normal pressure, the polymerization reaction is stopped, and the strands are discharged from the bottom of the polymerization vessel. After cooling and solidification, they are cut to form pellets of the phosphorus atom-containing flame-retardant polyester composition. got it The obtained polyester containing phosphorus atoms had an intrinsic viscosity of 0.75, a melting point of 239°C, and a phosphorus element content of 0.67 wt%.

(Method for producing polyester elastomer (A4))

A polyester containing 65% by mass of a high-melting point crystalline segment (H1) containing crystalline aromatic polyester as the main structural unit and 35% by mass of a low-melting point polymer segment (L1) containing aliphatic polyether as the main structural unit. Block copolymer (A1-2) was prepared. 101 parts of terephthalic acid, 50.0 parts of 1,4-butanediol, 71.0 parts of poly(oxytetramethylene) glycol with a number average molecular weight of about 1400, 0.06 parts of titanium tetrabutoxide, and 0.04 parts of mono-n-butyl-monohydroxytin oxide are added together in a helical form. It was poured into a reaction vessel equipped with a ribbon-type stirring blade, heated at 190 to 225°C for 3 hours, and an esterification reaction was performed while the reaction water was discharged to the outside of the system. To the reaction mixture was added 0.4 parts of tetra-n-butyl titanate, 0.1 part of “Irganox” 1098 (a hindered phenolic antioxidant manufactured by Ciba Geig), and then heated to 245°C, followed by 50 minutes. Over time, the pressure in the system was reduced to 27 Pa, and polymerization was performed for 2 hours and 50 minutes under those conditions. The obtained polymer was discharged into water in the form of a strand and cut into pellets. The melting point was 208°C.

(Method for producing polyester elastomer (A5))

A polyester containing 50% by mass of a high-melting point crystalline segment (H1) whose main structural unit is a crystalline aromatic polyester, and 50% by mass of a low-melting point polymer segment (L1) whose main structural unit is an aliphatic polyether. Block copolymer (A1-3) was prepared. 88 parts of terephthalic acid, 33.0 parts of 1,4-butanediol, 101 parts of poly(oxytetramethylene) glycol with a number average molecular weight of about 1400, 0.06 parts of titanium tetrabutoxide, and 0.04 parts of mono-n-butyl-monohydroxytin oxide are added together into a helical form. It was poured into a reaction vessel equipped with a ribbon-type stirring blade, heated at 190 to 225°C for 3 hours, and an esterification reaction was performed while the reaction water was discharged to the outside of the system. To the reaction mixture was added 0.4 parts of tetra-n-butyl titanate, 0.1 part of “Irganox” 1098 (a hindered phenolic antioxidant manufactured by Ciba Geig), and then heated to 245°C, followed by 50 minutes. Over time, the pressure in the system was reduced to 27 Pa, and polymerization was performed for 2 hours and 50 minutes under those conditions. The obtained polymer was discharged into water in the form of a strand and cut into pellets. The melting point was 182°C.

(Method for producing polyester (A6))

100 parts by weight of dimethyl terephthalate, 57.5 parts by weight of ethylene glycol, 0.03 parts by weight of magnesium acetate dihydrate, and 0.03 parts by weight of antimony trioxide were melted at 150°C in a nitrogen atmosphere. The temperature of this melt was raised to 230°C over 3 hours while stirring, methanol was distilled out, and the transesterification reaction was completed. After completion of the transesterification reaction, an ethylene glycol solution (pH 5.0) in which 0.005 parts by weight of phosphoric acid was dissolved in 0.5 parts by weight of ethylene glycol was added. The intrinsic viscosity of the polyester composition at this time was less than 0.2. Afterwards, the polymerization reaction reached a final temperature of 285°C and the pressure of the reaction system was reduced to 13 Pa to obtain polyester with an intrinsic viscosity of 0.65 and a melting point of 265°C.

(Method for producing polyester (A7))

A slurry of 1,100 parts by weight of terephthalic acid and 480 parts by weight of ethylene glycol was supplied over 3 hours to an esterification reaction tank maintained at a temperature of 245°C into which 1,950 parts by weight of bishydroxyethyl terephthalate was injected, and water generated during the esterification reaction was added to the esterification reaction tank maintained at 245°C. The esterification reaction was performed while distilling it out of the reaction system. 1300 parts by weight of the oligomer after reaction was transferred to a polycondensation reaction tank. Next, a previously prepared slurry of 46 parts by weight of (2-carboxyethyl)methylphosphinic acid and 150 parts by weight of ethylene glycol was added to the transferred oligomer 40 minutes before starting the polycondensation reaction, and then diantimony trioxide was added. 500 ppm was added, and then the temperature of the reaction system was gradually raised from 250°C to 290°C. At the same time, ethylene glycol was distilled off and the pressure of the reaction system was reduced to 50 Pa. Additionally, a slurry of (2-carboxyethyl)methylphosphinic acid and ethylene glycol was prepared 50 minutes before the start of addition of the slurry into the polycondensation reaction system. At the point when the predetermined stirrer torque is reached, nitrogen is introduced into the reaction system, the pressure is returned to normal pressure, the polymerization reaction is stopped, and the strands are discharged from the bottom of the polymerization vessel. After cooling and solidification, they are cut to form pellets of the phosphorus atom-containing flame-retardant polyester composition. got it The obtained polyester containing phosphorus atoms had an intrinsic viscosity of 0.72, a melting point of 245°C, and a phosphorus element content of 0.50 wt%.

[Example 1]

(pellet)

The polyester elastomer (A1) and the flame retardant (B1) were mixed to obtain pellets (A1-B1) containing the flame retardant and the polyester elastomer. In addition, (B1) used the organic phosphorus-containing compound “Fire Guard” FCX-210 manufactured by Teijin Co., Ltd.

(monofilament)

As the polymer used in the core portion, a pellet (A1-B1) containing a flame retardant and a polyester elastomer was used, and as the polymer used in the sheath portion, polyester (A3) was used, and the ratios of the core portion and sheath portion shown in Table 1 were used. This was spun to obtain a monofilament. Here, the monofilament is a core-sheath composite fiber, and the fraction of the core portion was 70 volume% and the fraction of the sheath portion was 30 volume%. Radioactivity was ○ for clogging of the filter, ○ for occurrence of scum, ○ for thread breakage, ○ for the number of occurrences of nepsa, and the overall evaluation of radioactivity was ○. Additionally, the dry heat shrinkage rate of the obtained monofilament was 23.0%. Additionally, the flame retardant contained in the sheath was phosphorus compound 1 (2-carboxyethyl(phenyl)phosphinic acid), and the phosphorus element content contained in the sheath was 0.7% by mass.

(Fabric font)

The obtained monofilament and twin yarns of 167detx false twisted polyester yarn were used as other yarns, and were knitted using a horizontal knitting machine so that the monofilament content of the fabric was 70% by mass, thereby obtaining a fabric. Next, the edge of the fabric was supported and attached with a frame member made of metal with a frame size of 500 mm The composition and performance of this fabric are shown in Table 1. This fabric has excellent radioactivity as the comprehensive evaluation of the radioactivity of the monofilament used in the fabric is ○, the combustibility of the fabric (horizontal method) is 0 mm/min, which means it has excellent combustibility, and when a load of 400N is applied to the fabric, The amount of deflection was 32 mm, and the overall evaluation of the fabric was ◎.

[Example 2] to [Example 10]

Fabrics and fabric bodies were produced and evaluated in the same manner as in Example 1, except that the ratio of core and sheath, flame retardant content, and phosphorus element content were changed as shown in Table 1. The results are shown in Table 1.

[Example 11]

Regarding the flame retardant contained in the core, the fabric and fabric body were produced and evaluated in the same manner as in Example 1, except that the following B2 was added to the flame retardant in Example 1. The results are shown in Table 1.

(B2): Flamestab NOR116FF, a hindered amine light stabilizer (HALS) manufactured by BASF Japan Co., Ltd.

[Example 12]

Fabrics and fabric bodies were produced and evaluated in the same manner as in Example 1, except that the flame retardant contained in the core was changed from Example 1 to B3 below. The results are shown in Table 1.

(B3): Aluminum phosphinate OP-1240 manufactured by Clariant Chemicals. It does not have a melting point below 300℃, and its decomposition temperature is above 300℃.

[Example 13]

Fabrics and fabric bodies were produced and evaluated in the same manner as in Example 1, except that the flame retardant contained in the core was changed from Example 1 to B4 below. The results are shown in Table 1.

(B4): Aluminum hydroxide (Nippon Keikinzoku Co., Ltd., SB303, average particle size 27㎛)

[Example 14]

Fabrics and fabric bodies were produced and evaluated in the same manner as in Example 1, except that the flame retardant contained in the sheath was changed from Example 1 to B3 below. The results are shown in Table 1.

(B3): Aluminum phosphinate OP-1240 manufactured by Clariant Chemicals. It does not have a melting point below 300℃, and its decomposition temperature is above 300℃.

[Example 15]

As the polymer used in the core, polyester elastomer (A1) and polyester elastomer (A2) were used in combination, and the fabric and fabric body were manufactured in the same manner as in Example 1, except for changes from Example 1. , evaluated. The results are shown in Table 2.

[Example 16]

As the polymer used in the sheath, polyester (A6), which does not contain elemental phosphorus as a flame retardant, was used, and the fabric and fabric body were manufactured in the same manner as in Example 1, except that there were changes from Example 1. , evaluated. The results are shown in Table 2.

[Example 17]

As the polymer used in the sheath, polyester (A7) copolymerized with phosphorus compound 2 was used, and the fabric and fabric body were manufactured in the same manner as in Example 1, except for changes from Example 1. , evaluated. The results are shown in Table 2. On the other hand, phosphorus compound 2 is (2-carboxyethyl)methylphosphinic acid, and the content of phosphorus element contained in the sheath portion was 0.5% by mass.

[Example 18]

Polyester elastomer (A4) was used as the polymer used in the core, and fabrics and fabric bodies were produced and evaluated in the same manner as in Example 1, except for changes from Example 1. The results are shown in Table 2.

[Example 19]

Polyester elastomer (A5) was used as the polymer used in the core portion, and fabrics and fabric bodies were produced and evaluated in the same manner as in Example 1, except for changes from Example 1. The results are shown in Table 2.

[Comparative Example 1] to [Comparative Example 6]

Fabrics and fabric bodies were produced and evaluated in the same manner as in Example 1, except that the ratio of the core and sheath, the flame retardant content, and the phosphorus element content were changed as shown in Table 2. The results are shown in Table 3.

1: Fabric 1a: Opening
2: frame member 2a: first frame member
2b: second frame member 3: fabric body

Claims (7)

Contains 50% by mass or more of monofilament,
The monofilament is a core-sheath composite fiber having a core and a sheath,
The errand is,
Contains 60 to 90% by volume relative to the core-sheath composite fiber, and
Comprising a first flame retardant and a polyester elastomer,
In the beginning,
Contains 10 to 40% by volume relative to the core-sheath composite fiber, and
A fabric made of polyester excluding the polyester elastomer of the core portion. According to claim 1,
The fabric is a letter,
The above-mentioned fabric has a piece density of 10 to 50 pieces/25.4 mm in at least one of the warp direction and the weft direction,
A fabric where the fineness of the monofilament is 300 to 3000 dtex. The method of claim 1 or 2,
The first flame retardant is,
Contains at least one member selected from the group consisting of organic phosphoric acid ester compounds, metal phosphinic acid salts, and triazine skeleton-containing compounds,
A fabric containing 1 to 30% by mass based on the core portion. The method according to any one of claims 1 to 3,
The first portion includes a second flame retardant,
The second flame retardant is,
Contains at least one of an arylphosphinic acid compound or an alkylphosphinic acid compound,
A fabric containing 0.3 to 1.1% by mass in terms of elemental phosphorus relative to the sheath. A fabric body comprising the fabric according to any one of claims 1 to 4 and a frame member. According to claim 5,
The fabric body is formed without sewing and without adhesiveness. A sheet using the fabric according to claim 5 or 6.