US20190301082A1 - Fabric - Google Patents

Fabric Download PDF

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Publication number
US20190301082A1
US20190301082A1 US16/265,967 US201916265967A US2019301082A1 US 20190301082 A1 US20190301082 A1 US 20190301082A1 US 201916265967 A US201916265967 A US 201916265967A US 2019301082 A1 US2019301082 A1 US 2019301082A1
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US
United States
Prior art keywords
fabric
coating layer
water
oil repellent
deodorant
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
US16/265,967
Other languages
English (en)
Inventor
Rie Hayashi
Chika NEMOTO
Kohei Ohara
Takayuki Oishi
Tatsuya FUKUI
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Honda Motor Co Ltd
TB Kawashima Co Ltd
Original Assignee
Honda Motor Co Ltd
TB Kawashima Co Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Honda Motor Co Ltd, TB Kawashima Co Ltd filed Critical Honda Motor Co Ltd
Assigned to HONDA MOTOR CO., LTD. reassignment HONDA MOTOR CO., LTD. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: HAYASHI, RIE, NEMOTO, CHIKA
Assigned to TB KAWASHIMA CO., LTD. reassignment TB KAWASHIMA CO., LTD. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: FUKUI, TATSUYA, OHARA, KOHEI, OISHI, TAKAYUKI
Publication of US20190301082A1 publication Critical patent/US20190301082A1/en
Abandoned legal-status Critical Current

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    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
    • D06N3/0002—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the substrate
    • D06N3/0015—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the substrate using fibres of specified chemical or physical nature, e.g. natural silk
    • D06N3/0036—Polyester fibres
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
    • D06N3/0056—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the compounding ingredients of the macro-molecular coating
    • D06N3/0059—Organic ingredients with special effects, e.g. oil- or water-repellent, antimicrobial, flame-resistant, magnetic, bactericidal, odour-influencing agents; perfumes
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
    • D06N3/0056—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the compounding ingredients of the macro-molecular coating
    • D06N3/0063—Inorganic compounding ingredients, e.g. metals, carbon fibres, Na2CO3, metal layers; Post-treatment with inorganic compounds
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
    • D06N3/04—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • D06N3/042—Acrylic polymers
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
    • D06N3/04—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • D06N3/047—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds with fluoropolymers
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
    • D06N3/18—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with two layers of different macromolecular materials
    • D06N3/183—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with two layers of different macromolecular materials the layers are one next to the other
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2209/00—Properties of the materials
    • D06N2209/06—Properties of the materials having thermal properties
    • D06N2209/067—Flame resistant, fire resistant
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2209/00—Properties of the materials
    • D06N2209/14—Properties of the materials having chemical properties
    • D06N2209/142—Hydrophobic
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2209/00—Properties of the materials
    • D06N2209/14—Properties of the materials having chemical properties
    • D06N2209/145—Oleophobic
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2209/00—Properties of the materials
    • D06N2209/14—Properties of the materials having chemical properties
    • D06N2209/147—Stainproof, stain repellent
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2209/00—Properties of the materials
    • D06N2209/16—Properties of the materials having other properties
    • D06N2209/165—Odour absorbing, deodorizing ability

Definitions

  • the present invention relates to a functional fabric. More specifically, the present invention relates to a fabric that has deodorant performance and is less likely to generate water spots.
  • a fabric used for interior of, for example, cars, ships, and airplanes for example, a fabric used for a seat of vehicles such as a car and for trim members such as a door lining
  • a fabric used for a seat of vehicles such as a car and for trim members such as a door lining
  • the fabric may be coated with a coating composition containing a deodorant to impart deodorant performance to the fabric.
  • a coating composition containing a deodorant to impart deodorant performance to the fabric.
  • JP-A-2008-56901 discloses a fabric having a deodorant property and flame retardancy.
  • Coating a fabric with a coating composition containing a deodorant is capable of imparting deodorant performance to the fabric, whereas the fabric has a problem of being easily discolored by, for example, hot water or water spilled thereon and not returning to the original color even when dried (that is, the fabric is likely to generate water spots).
  • An object of the present invention is to solve the above problems and to provide a fabric that has excellent deodorant performance and is less likely to generate water spots.
  • the present inventors have succeeded in solving the problems by forming, on one surface of a fabric, a coating layer (first coating layer) containing a prescribed amount of a fluorinated water-and-oil repellent agent and further forming, on the coating layer, a coating layer (second coating layer) containing a deodorant.
  • a fabric according to the present invention includes, on one surface (in particular, a rear surface) thereof a first coating layer containing a fluorinated water-and-oil repellent agent and a second coating layer containing a deodorant,
  • the first coating layer existing between the fabric and the second coating layer.
  • coating one surface of a fabric with a composition containing a deodorant is capable of imparting a deodorant property to the fabric but makes the fabric likely to generate water spots. Even when a water-and-oil repellent agent is added to the coating composition containing a deodorant and thereby a coating layer is formed, the degree of water spots is not sufficiently improved.
  • a water-and-oil repellent coating layer and a deodorant coating layer in the order, from the fabric, of the water-and-oil repellent coating layer (first coating layer) and the deodorant coating layer (second coating layer), and the amount of a fluorinated water-and-oil repellent agent contained in the first coating layer is set at a prescribed amount, to succeed in manufacturing a fabric that has an excellent deodorant property (odor reducing property) and is less likely to generate water spots.
  • the second coating layer preferably further contains a flame retardant. Addition of a flame retardant to the second coating layer is capable of enhancing flame retardancy of the fabric.
  • the fabric is preferably a fabric impregnated with a fluorinated water-and-oil repellent agent. Impregnation of the fabric with a fluorinated water-and-oil repellent agent is capable of imparting high stain resistance against oil and moisture to the fabric.
  • the first coating layer further contains a flame retardant and a binder resin contained in the first coating layer is an acrylic resin.
  • Use of an acrylic resin as the binder resin (base resin) of the first coating layer is capable of improving texture of the fabric, and addition of a flame retardant to the first coating layer is capable of further enhancing the flame retardancy.
  • FIGS. 1 a and 1 b are views that show a fabric according to the present invention, with FIG. 1 a showing a fabric 1 that includes, on a rear side thereof, a first coating layer 2 (a coating layer containing a fluorinated water-and-oil repellent agent) and a second coating layer 3 (a coating layer containing a deodorant), and FIG. 1 b showing a fabric having a foam material sheet 4 further fixed thereto.
  • a first coating layer 2 a coating layer containing a fluorinated water-and-oil repellent agent
  • a second coating layer 3 a coating layer containing a deodorant
  • a fabric according to the present invention includes, on one surface (in particular, a rear surface) thereof, a fluorinated water-and-oil repellent coating layer and a deodorant coating layer, in which the fluorinated water-and-oil repellent coating layer is disposed between the fabric and the deodorant coating layer.
  • the fabric has, as shown in the section of Examples, a 4-hour-later deodorization rate (odor reduction rate) of preferably 80% or more, (more preferably 85% or more, further preferably 90% or more) for each of ammonia, hydrogen sulfide, and acetaldehyde.
  • a 4-hour-later deodorization rate odor reduction rate
  • the fabric achieves grade 4 or higher in rating of water spots on a front surface of the fabric that is performed 24 hours after 4 mL of distilled water at 80° C. was dropped onto the front surface, a rear surface of the fabric is not wet, and the fabric achieves grade 4 or higher in rating of water spots on the rear surface of the fabric.
  • the fabric according to the present invention preferably has flame retardancy. Specifically, it is preferable that in a test performed in accordance with “Flammability of Interior Materials” specified in Federal Motor-Vehicle Safety Standard (FMVSS), the fabric is evaluated as “N” that is given when the fabric is not ignited even with 15-second flame application or when the fabric is ignited with the flame application but the flame is extinguished before crossing the marked line A (burning rate measuring start line), or the fabric is ignited with the flame application but has a burning rate of 101 mm/min or less after the flame crosses the marked line A. Particularly, the fabric is preferably evaluated as “N.”
  • FMVSS Federal Motor-Vehicle Safety Standard
  • the fabric according to the present invention preferably has stain resistance. More specifically, the fabric preferably has no oil stain on front and rear surfaces of the fabric and on a soft wipe after 24 hours at 83° C. in a salad oil stain resistance test described in the section of Examples.
  • the fabric according to the present invention preferably has good texture (the fabric is soft). Specifically, the fabric preferably has a vertical stiffness of 80 mm or less, in particular, 70 mm or less in a stiffness test indicated in the section of Examples.
  • a ground fabric used in the present invention is preferably a polyester fabric high in flame retardancy.
  • the polyester fabric in the present invention means a fabric containing polyester fiber, and may be not only a woven fabric, a knitted fabric, and a nonwoven fabric composed of polyester fiber alone but also any of a blended fabric, an interknitted fabric, and the like containing polyester fiber and other fibers (natural fibers such as cotton and wool, or chemical fibers such as a polyamide, rayon, and acrylic) in combination.
  • the proportion of the polyester fiber in fibers constituting the fabric is preferably 60% by weight or more, more preferably 70% by weight or more, particularly preferably 80% by weight or more, further preferably 90% by weight or more.
  • a fabric that is composed of polyester fiber and has a thickness of 0.2 to 3.0 mm (basis weight: 100 to 700 g/m 2 ), in particular, a thickness of 0.4 to 2.6 mm (basis weight: 200 to 500 g/m 2 ).
  • the ground fabric used in the present invention is preferably a fabric impregnated with a fluorinated water-and-oil repellent agent.
  • the fluorinated water-and-oil repellent agent is a compound that has a fluoroalkyl group obtained by substituting all or a part of hydrogen atoms in a hydrocarbon group with a fluorine atom(s).
  • a polymer is preferably used that contains a monomer having a perfluoroalkyl group. From a viewpoint of environmental preservation and safety, the perfluoroalkyl group preferably has 6 carbon atoms.
  • fluorinated water-and-oil repellent agent examples include a fluorinated water-and-oil repellent agent sold under the name of AsahiGuard E-SERIES from AGC Inc. and a fluorinated water-and-oil repellent agent sold under the name of NK GUARD S Series from NICCA CHEMICAL CO., LTD.
  • the fluorinated water-and-oil repellent agent used for immersing the fabric may be one agent or a plurality of agents (for example, two to three agents).
  • the fabric impregnated with the fluorinated water-and-oil repellent agent means a fabric having the fluorinated water-and-oil repellent agent attached not only to a surface thereof but also to fibers therein.
  • an immersion treatment generally called a padding treatment or a dip-nip treatment.
  • an immersion treatment generally called a padding treatment or a dip-nip treatment.
  • the fabric impregnated with the fluorinated water-and-oil repellent agent by preparing an aqueous treatment liquid containing the fluorinated water-and-oil repellent agent(s) (solid content) in an amount of 1.0 to 5.0% by weight, more preferably 1.5 to 3.5% by weight, immersing the polyester fabric in the treatment liquid (for example, 2 to 5 minutes) and squeezing the fabric with, for example, rollers (mangles) to make the entire fabric contain the treatment liquid, and then drying the fabric.
  • Appropriate dry conditions are, for example, 110 to 170° C., in particular, 120 to 160° C. for about 1 to 5 minutes.
  • the amount of the fluorinated water-and-oil repellent agent(s) impregnated into the fabric by this stain resistant finish can be calculated by the concentration of the fluorinated water-and-oil repellent agent(s) in the treatment liquid and the squeezing rate.
  • the impregnated amount, per unit area of the fabric, of the fluorinated water-and-oil repellent agent(s) contained in the dried fabric is appropriately 2.0 g/m 2 to 8.0 g/m 2 , more preferably 3.0 g/m 2 to 7.0 g/m 2 , particularly preferably 4.0 g/m 2 to 6.5 g/m 2 .
  • a coating layer (first coating layer) containing a fluorinated water-and-oil repellent agent is formed on one (in particular, a rear surface) of surfaces of the ground fabric having the stain resistant finish optionally performed thereon.
  • the fluorinated water-and-oil repellent agent in the first coating layer it is possible to use those described above as the fluorinated water-and-oil repellent agent used in the immersion treatment.
  • a fluorinated water-and-oil repellent agent may be used that is the same or different from that used in the immersion treatment.
  • One fluorinated water-and-oil repellent agent may be used alone or a plurality of fluorinated water-and-oil repellent agents may be used in combination.
  • the content, per unit area of the fabric, of the fluorinated water-and-oil repellent agent(s) contained in the first coating layer is preferably 1.3 g/m 2 to 5.0 g/m 2 .
  • the content, per unit area of the fabric, of the fluorinated water-and-oil repellent agent(s) is more preferably 1.5 g/m 2 to 4.5 g/m 2 .
  • the first coating layer may contain one or two or more flame retardants.
  • the flame retardant that can be used in the first coating layer is preferably a phosphorus flame retardant having a solubility in water at 20° C. of 4% (4 g/100 g of water) or less.
  • a flame retardant is exemplified that is selected from the group consisting of phosphonic acid esters, phosphoric acid amides, phosphoric acid ester amides, aromatic phosphoric acid esters, and halogen-containing phosphoric acid esters.
  • an organic phosphorus flame retardant is preferable.
  • a preferable flame retardant is a phosphonic acid ester-based flame retardant and/or melamine phosphate.
  • a second coating layer containing at least one deodorant is formed on the first coating layer formed on one (in particular, a rear surface) of surfaces of the fabric.
  • the deodorant used for the second coating layer it is preferable to use inert inorganic porous particles (carriers) supporting a deodorant component.
  • Such inorganic porous particles supporting a deodorant component are capable of preventing pieces of the deodorant component from directly contacting with each other or the deodorant component from being inhibited due to existence of a flame retardant.
  • an amine compound, a metal compound, or cyclodextrin each supported by a different carrier are, for example, silica, a silica-alumina composite, and a layered double hydroxide.
  • a compound having a primary amine group in its molecule such as a hydrazine compound that is particularly effective for adsorbing, for example, formaldehyde, acetaldehyde, and acetic acid.
  • hydrazine compound examples include adipic acid dihydrazide, azelaic acid dihydrazide, succinic acid dihydrazide, glutaric acid dihydrazide, oxalic acid dihydrazide, suberic acid dihydrazide, sebacic acid dihydrazide, dodecanedioic acid dihydrazide, pimelic acid dihydrazide, malonic acid dihydrazide, isophthalic acid dihydrazide, terephthalic acid dihydrazide, and polyacrylic acid dihydrazide.
  • the metal compound examples include metal compounds containing zinc or copper that exhibits a deodorant effect of deodorizing hydrogen sulfide and mercaptans, such as an oxide, a hydroxide, a chloride, a sulfate, an acetate, and a citrate of zinc or copper.
  • metal compounds containing zinc or copper that exhibits a deodorant effect of deodorizing hydrogen sulfide and mercaptans, such as an oxide, a hydroxide, a chloride, a sulfate, an acetate, and a citrate of zinc or copper.
  • zinc silicate and zinc oxide are particularly useful.
  • the content, per unit area of the fabric, of the deodorant(s) contained in the second coating layer is preferably 5 g/m 2 to 20 g/m 2 , more preferably 7 g/m 2 to 15 g/m 2 , particularly preferably 8 g/m 2 to 13 g/m 2 .
  • the flame retardant contained in the second coating layer is preferably substantially free of halogen.
  • a flame retardant having a surface thereof treated with silicone or having a low solubility in water such that functionality of the flame retardant is not impaired by combination use with the deodorant, and particularly, useful are silicone-coated ammonium polyphosphate or a metal dialkylphosphinate.
  • metal dialkylphosphinate exemplified as an alkyl group are methyl, ethyl, n-propyl, isopropyl, n-butyl, tertiary butyl, n-pentyl, and/or phenyl
  • exemplified as a metal is aluminum, magnesium, calcium, titanium, zinc, tin, or zirconium.
  • Aluminum diethylphosphinate is particularly preferable.
  • the flame retardant substantially free of halogen means that the flame retardant may contain a halogen in as small an amount as recognized as an impurity or within a range not to impair the effects of the present invention.
  • the content, per unit area of the fabric, of the flame retardant(s) contained in the second coating layer is preferably 15 g/m 2 to 45 g/m 2 , more preferably 20 g/m 2 to 40 g/m 2 , particularly preferably 25 g/m 2 to 37 g/m 2 .
  • Addition of a water-and-oil repellent agent to the second coating layer decreases peeling strength between the fabric and a foam material sheet when the foam material sheet is fixed to the fabric (see FIG. 1 b ), so that the second coating layer is better off being substantially free of water-and-oil repellent agents (the content, per unit area of the fabric, of a water-and-oil repellent agent contained in the second coating layer is preferably less than 0.1 g/m 2 , more preferably 0 g/m 2 ).
  • Compositions for forming the first and second coating layers of the present invention contain a binder that attaches (fix) the fluorinated water-and-oil repellent agent or the deodorant to the fabric.
  • a binder that attaches (fix) the fluorinated water-and-oil repellent agent or the deodorant to the fabric.
  • a preferable binder include a polyester resin, an acrylic resin, and a urethane resin. It is preferable to use a polyester resin when the flame retardancy is emphasized, while it is preferable to use an acrylic resin when costs or texture is emphasized.
  • polyester resin As the polyester resin, the acrylic resin, and the urethane resin, it is possible to use commercially available polyester resins, acrylic resins, and urethane resins that are used as binders for a usual fabric coating composition.
  • each binder is desirably a soft binder.
  • the acrylic resin desirably has a glass-transition temperature (Tg) of ⁇ 30° C. to ⁇ 45° C.
  • the urethane resin desirably has a minimum film forming temperature (MFT) of 0° C. to 5° C.
  • the first and second coating compositions may contain a thickener.
  • a thickener it is possible to use, for example, a cellulose-based thickener, an acrylic acid-based thickener, and a urethane associative thickener.
  • the content, per unit area of the fabric, of the thickener contained in the coating layer is usually about 0.3 to 5.0 g/m 2 .
  • the viscosity of the first and second coating compositions is appropriately about 20,000 to 70,000 mPa ⁇ s, particularly preferably about 30,000 to 55,000 mPa ⁇ s.
  • the viscosity of the coating composition in the present specification means viscosity measured using a B-type viscometer (BH type), at a measurement temperature of 20° C., with a rotor No. 6, at a rotation speed of 10 rpm, after 30 seconds from the start of the rotation.
  • BH type B-type viscometer
  • the first and second coating compositions can be applied to the fabric using, for example, a knife coater, a comma coater, a bar coater, a die coater, a kiss-roll coater, or a gravure coater.
  • the dry conditions after the application of the first and second coating compositions to the fabric can be set at, for example, 110 to 170° C., in particular, 120 to 160° C. for about 2 to 5 minutes.
  • the fabric according to the present invention may have a foam material sheet fixed to a coating side (on the second coating layer) thereof (see FIG. 1 b ).
  • the foam material sheet include polyurethane foam (e.g., slab urethane) having a thickness of 2.0 to 10 mm.
  • Such a laminate composite formed of the fabric and the foam material sheet is suitably used as a skin material for a seat of vehicles such as a car (usually, a molded product formed of a urethane cushion material).
  • Examples of a method of fixing the foam material sheet to one surface of the fabric include flame lamination which involves melting a front layer on one surface of the foam material sheet with a gas burner and fusion-bonding the foam material sheet to one surface (on the second coating layer) of the fabric having the first and second coating layers formed thereon.
  • Polyester fabrics (polyester 100%: basis weight 280 g/m 2 ) dyed in black with disperse dye were subjected to coating to manufacture the fabrics shown in Table 1.
  • the coating composition for forming a coating layer on each of the polyester fabrics was adjusted to have a viscosity in a range of 34,000 mPa ⁇ s to 36,000 mPa ⁇ s.
  • the coating layer was formed on a rear surface of the fabric with a knife coater.
  • the water-and-oil repellent agent used in the first coating layer and the second coating layer was a fluorinated water-and-oil repellent agent sold under the name of NK GUARD S-0545 from NICCA CHEMICAL CO., LTD.
  • the acrylic resin used in the first coating layer was an acrylic resin sold under the name of Movinyl 7400 from Japan Coating Resin Co., Ltd.
  • the acrylic resin used in the second coating layer was an acrylic resin sold under the name of VONCOAT AB901 from DIC Corporation.
  • the flame retardant used as the flame retardant was aluminum diethylphosphinate and used as the deodorants were KD-211G (zinc oxide supported by porous silica) sold from Rasa Industries, Ltd. and KESMON NS-240 (an amine compound supported by porous silica) sold from Toagosei Co., Ltd.
  • the processed fabrics shown in Table 1 were tested, according to the following methods, for their water spots, deodorant performance, stain resistant performance, flame retardant performance, and stiffness.
  • the test was performed with three odor components.
  • the deodorization rates (odor reduction rates) of the processed fabric were calculated for each of the odor components. Specifically, a deodorant test piece (5 cm ⁇ 5 cm processed fabric) was put in a 3-L Tedlar bag into which was injected 2 L of a gas containing one odor component for measurement (with the odor component's initial concentration adjusted to 100 ppm for ammonia, to 50 ppm for hydrogen sulfide, or to 50 ppm for acetaldehyde), and the bag was sealed. The bag was left at normal temperature for 4 hours and then the residual concentration of the odor component was measured, and the deodorization rate was calculated.
  • test piece with an about 10 ⁇ 10 cm square was prepared from each of the samples (processed fabrics).
  • a soft wipe (Elleair Prowipe) was placed on a tray, and the test piece was put on the soft wipe with its coated surface (rear surface) downward.
  • Salad oil was dropped in 5 spots on the test piece with a dropper such that each droplet had a diameter of about 5 mm or 0.05 mL.
  • the tray was left to stand at normal temperature for 24 hours in a normal temperature test (I), and the tray was left to stand in a Geer oven at 83° C. for 24 hours in a high-temperature test (II). After 24 hours, the test piece was observed whether a front surface thereof was wet at the salad oil-dropped spots (whether an oil stain was generated) and whether an oil stain due to the salad oil was present on the rear surface thereof and the soft wipe. A test piece was determined to be passed ( ⁇ ) that had no oil stain on the front and rear surfaces thereof and on the soft wipe placed underneath the test piece.
  • the evaluation “N” was given to a test piece (processed fabric) that was not ignited even with 15-second flame application or that was ignited with the flame application but the flame was extinguished before crossing the marked line A.
  • the stiffness was measured by a so-called cantilever method.
  • test pieces with 25 mm (width) and 200 mm (length) were taken out from the processed fabric along the vertical line (long axis) of the fabric, a test piece was put on a horizontal table having a 45-degree slope on one end of the table and a smooth surface, with one end of the test piece accurately arranged on the horizontal table's slope-side end, and the position (A) of the other end of the test piece was read with a scale.
  • a pressing plate having almost the same size as the test piece was slid toward the slope at a speed of about 10 mm/s while gently pressing the test piece, and when the one end of the test piece contacted with the slope, the position (B) of the other end was read with the scale.
  • the stiffness was represented by the movement distance (A-B) of the test piece (the smaller the numerical value of stiffness is, the softer the fabric is, and the larger the numerical value is, the harder the fabric is).
  • the table shows the average value (mm) of three measured values.
  • the fabric (No. 3) that included the deodorant coating layer containing the stain resistant agent (fluorinated water-and-oil repellent agent) did not also exhibit an effect of improving the degree of water spots.
  • the fabric (No. 4) that included an acrylic resin coating layer between the fabric and the deodorant coating layer improved the degree of water spots on the front surface of the fabric but was not capable of preventing the degree of water spots on the rear surface of the fabric.
  • the fabrics (Nos. 5 and 6) that included a coating layer further containing a filler between the fabric and the deodorant coating layer only improved the degree of water spots on the front surface of the fabric or did not even improve the degree of water spots on the front surface of the fabric.
  • the fabric (No. 7) that included the deodorant coating layer containing the stain resistant agent (fluorinated water-and-oil repellent agent) and further included an acrylic resin coating layer between the fabric and the deodorant coating layer only improved the degree of water spots on the front surface of the fabric but did not improve the degree of water spots on the rear surface of the fabric.
  • the fabric (No. 8) having a small amount of the fluorinated water-and-oil repellent agent only improved the degree of water spots on the front surface of the fabric
  • the fabrics (Nos. 9 to 11) having an increased amount of the fluorinated water-and-oil repellent agent improved the degree of water spots on both the front and rear surfaces of the fabric.
  • the disposition of the first coating layer containing the fluorinated water-and-oil repellent agent was capable of improving the degree of water spots but made the stain resistant performance insufficient. Therefore, processed fabrics were prepared by impregnating ground fabrics with a fluorinated water-and-oil repellent agent according to a dip-nip method and then disposing the first and second coating layers on the ground fabrics, and the processed fabrics were subjected to the same tests as in Table 1.
  • the impregnation of the ground fabrics with the fluorinated water-and-oil repellent agent improved the stain resistant performance of all the processed fabrics in the normal temperature test. Further, the fabrics that included the first coating layer having an amount, per unit area of the fabric, of the fluorinated water-and-oil repellent agent of 1.3 g/m 2 or more also achieved the acceptable level of the stain resistant performance at 83° C.
  • the fabric (No. 16) that included the deodorant coating layer containing the stain resistant agent did not also improve the degree of water spots.
  • the fabric (No. 17) that included an acrylic resin coating layer between the fabric and the deodorant coating layer improved the degree of water spots on the front surface of the fabric but was not capable of improving the degree of water spots on the rear surface of the fabric.
  • the fabrics (Nos. 18 and 19) that included a coating layer further containing a filler between the fabric and the deodorant coating layer improved the degree of water spots on the front surface of the fabric but did not improve the degree of water spots on the rear surface of the fabric.
  • the fabric (No. 20) that included the deodorant coating layer containing the stain resistant agent (fluorinated water-and-oil repellent agent) and further included an acrylic resin coating layer between the fabric and the deodorant coating layer only improved the degree of water spots on the front surface of the fabric but did not improve the degree of water spots on the rear surface of the fabric.
  • the fabric (No. 21) having a small amount of the fluorinated water-and-oil repellent agent only improved the degree of water spots on the front surface of the fabric
  • the fabrics (Nos. 22 to 24) having an increased amount of the fluorinated water-and-oil repellent agent improved the degree of water spots on both the front and rear surfaces of the fabric.
  • the ground fabric subjected to the dip-nip stain resistant treatment is capable of improving the stain resistant performance at normal temperature but is not capable of improving the degree of water spots on the fabric, and it is possible to improve the degree of water spots and the stain resistant performance at 83° C. by disposing the coating layer (first coating layer) containing a sufficient amount of the fluorinated water-and-oil repellent agent between the fabric and the deodorant coating layer (second coating layer).
  • the polyester resin used in the first coating layer of the fabric Nos. 27 to 30 in Table 3 was a polyester resin sold under the name of PLAS COAT Z-880 from GOO Chemical Co., Ltd.
  • the flame retardant (solubility in water at 20° C.: 4.0% or less) used in the first coating layer of the fabric Nos. 31 and 32 in Table 3 was a mixture of melamine phosphate (manufactured by Shin Nakamura Chemical Co., Ltd.) and a phosphonic acid ester-based flame retardant sold under the name of SY-TC1 from SHINYO Co., Ltd. (weight ratio between active substances 1:1).
  • the fabric according to the present invention is suitably used as an interior fabric of vehicles such as a car because it solves the problems of the interior fabric that an odor on the fabric is likely to remain and has difficulty being washed or cleaned.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Inorganic Chemistry (AREA)
  • Laminated Bodies (AREA)
  • Treatments For Attaching Organic Compounds To Fibrous Goods (AREA)
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CN100515500C (zh) * 2003-11-14 2009-07-22 出光技优股份有限公司 除臭剂及除臭性制品
JP4440054B2 (ja) * 2004-09-17 2010-03-24 名古屋油化株式会社 難燃性材料
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