WO1994003393A1

WO1994003393A1 - Heat and flame resisting cushion material and seat for vehicle

Info

Publication number: WO1994003393A1
Application number: PCT/JP1993/001093
Authority: WO
Inventors: Tatuo Yamaguchi; Makoto Yoshida; Nobuo Takahashi; Takeo Kimura
Original assignee: Teijin Limited
Priority date: 1992-08-04
Filing date: 1993-08-04
Publication date: 1994-02-17
Also published as: EP0622332B1; DE69319577T2; DE69319577D1; EP0622332A1; JP3527507B2; EP0622332A4

Abstract

A heat and flame resisting cushion material in which fire resisting short crimped fibers and elastic thermoplastic fibers are mixed and dispersed in an aggregate of short non-elastic crimped fibers with the interlacing points between the elastic fibers and other fibers thermally fused. The cushion material may consist of an inner layer of a fiber aggregate and an outer layer surrounding the inner layer and composed of the same cushion material as described above. These cushion materials are useful for a seat for a vehicle, such as an airplane and a racing car.

Description

Light heat-resistant and flame-retardant cushioning material and vehicle seat technology

The present invention relates to a cushion material having heat resistance and flame retardancy, and a vehicle sheet formed by molding the cushion material.

Background technology

In recent years, with the sophistication of lifestyle, furniture and bedding, in particular, beds for elderly people and hospitals, and cushions for seats in various transportations have been required to have remarkable heat resistance and flame retardancy. It has come. Particularly for aircraft seat cushions, protecting the precious lives of people from flames and other matters is the primary priority. Therefore, extremely strict flame-retardant standards are determined by the United States Federal Aviation Administration (FAA) standards. That is a well-known fact. At present, the industry is technically responding to these demands in the form of an improvement on the urethane foam that has been widely used in the past. That is, in the production process of urethane foam, various flame retardants such as a phosphorus-based flame retardant are added to achieve flame retardancy.

However, the flame-retardant resin obtained by such means has a hard feel and a high density, and the cushion material itself becomes heavier in inverse proportion to the improvement in flame retardancy. Some disadvantages have been pointed out that are not preferred as shot materials. Naturally, cushioning materials must be comfortable, cushioning and as light as possible. In particular, light vehicles Quantification and weight reduction of aircraft seats are immutable propositions, and their demands have been increasing in recent years. In that sense, the properties of flame-retardant urethanes are by no means favorable. Urethane was also a problem in terms of recycling and industrial disposal. Heretofore, there has not been found any material which has satisfactory cushioning properties and flame retardancy in place of the flame retardant urethane.

On the other hand, besides urethane, other types of cushioning materials, such as polyester woven stuffed cotton, resin cotton bonded with polyester fiber, and solid cotton bonded with a low melting point binder have begun to be used. However, unfortunately, the morphology of the fibers and the fixation of the adhesive are not stable, causing the fibers to lose their shape during use, the fibers to move and the crimps to loosen, resulting in bulkiness and rebound. Even if it was greatly reduced, it lacked the basic properties required of cushioning materials, which could not be used comfortably over a long period of time. In addition, even in a cushion material containing these polyester fibers as a main material, the heat resistance and flame retardancy aimed at by the present invention could not be expected.

Disclosure of the invention

An object of the present invention is to provide a comfortable and lightweight cushioning material, which is mainly made of easily disposable textiles, has excellent flame retardancy and heat resistance, and a vehicle sheet using the cushioning material. To do that.

According to one aspect of the present invention, there is provided a flame-resistant crimped staple fiber having a weight retention rate of 35% or more by a flameless test method in a matrix comprising an inelastic crimped staple fiber assembly, and a thermoplastic resin. Heat-resistant, characterized in that the elastic fibers are mixed and dispersed, and at least a part of the entanglement point between the thermoplastic elastic fibers and other fibers is heat-sealed. Provides flammable cushioning material.

In another aspect, the present invention has a two-layer structure including an inner layer made of a fiber assembly and an outer layer surrounding the inner layer, and the outer layer is made of a matrix made of an inelastic crimped short fiber assembly. In addition, a flame-resistant crimped short fiber having a residual weight ratio of 35% or more by a flameless test method and thermoplastic elastic fibers are mixed and dispersed, and the entanglement point between the thermoplastic elastic fibers and other fibers. To provide a heat-resistant and flame-retardant cushion material characterized in that at least a part thereof is heat-sealed. The present invention provides, in still another aspect, a vehicle seat formed by molding the cushion material as described above.

BEST MODE FOR CARRYING OUT THE INVENTION The matrix of the cushion material of the present invention is composed of an aggregate of inelastic crimped short fibers. Preferred materials for inelastic crimped short arrowheads include polyester arrowheads and aramid arrowheads. Non-elastic polyester crimped short fibers include ordinary polyethylene terephthalate, polybutylene terephthalate, polytetramethylene terephthalate, and polyhexamethylene terephthalate. Rate, Poly 1,4-Dimethylcyclohexaneterate, Polyethylene naphthate, Polypivalolactone, or a short arrowhead made of poly (copolyester) thereof, or a blend of these fibers And a composite fiber composed of two or more of the above-mentioned polyester components. In order to improve the flame retardancy and heat resistance of these polyester fibers, those obtained by copolymerizing or blending a phosphorus-based or haptic-based compound are particularly preferred. In addition, as inelastic crumb short fibers Are meta- and para-aramid fibers, but among them are simply flame retardancy and heat resistance as well as mechanical properties such as strong modulus, or comprehensive properties such as crimp imparting property and crimp toughness. Excellent metalamide fibers are particularly preferred.

The cross-sectional shape of the inelastic crimped short fiber is not particularly limited, and may be any of a circular shape, a flat shape (an elongated cross-section), an irregular shape, and a hollow shape. Further, the fineness of the inelastic crimped short textile is preferably in the range of 4 to 300 denier, particularly preferably in the range of 6 to 100 denier. If the weave of this single fiber is too small, the density of the cushion material tends to increase, and the elasticity of the cushion material itself tends to decrease. Conversely, if the degree of single-weave arrowhead is too large, handling properties, especially web forming properties, will deteriorate. In addition, when the weave degree is large, the number of components becomes too small, so that the elasticity of the cushion material is hardly expressed, and at the same time, the durability tends to decrease. Also, the feeling becomes coarse and hard.

An important property of the inelastic short fibers constituting the matrix of the cushion material of the present invention is crimping. Crimp is an important factor for imparting bulkiness and cushioning to the cushion material, and is also an important factor for reducing the weight of the cushion. Is a crimp characteristics, initial bulk properties ^{4 0~ 1 2 0 cm 3 /} gr Dearuko and is laid ^{like, 5 0~ 1 2 0 cm 3} / gr Gayo Ri preferred lay, 7 0-1 2 0 cm ³ / gr is best. Et al is, 1 0 gr / cm under ² loading bulk resistance lay preferred is ^{1 5~ 5 0 cm 3 Zgr,} 2 0~ 5 0 cm 3 / gr is rather more preferable, ³ 0~ 5 0 cm 3 / gr is the best. Initial bulk properties and 1 0 gr / cm under ² Load bulk resistance in here is measured under a load of respectively 0. 5 gr / cm ² and 1 0 gr / cm ² in compliance with JIS 1015. Initial and 10 gr / cm ² load If the bulk under the weight is larger than the above value, the cardability is poor, while if it is less than the above value, the cushioning property of the obtained cushion material is poor. .

In general, the bulkiness of short fibers is 5 to 15 pieces / inch, especially 8 to 15 inches, and the crimp ratio is 15 to 35.

%, Especially at 20-35%. Here, the number of crimps and the crimp ratio are measured in accordance with JIS 1015.

The desired bulkiness described above can be obtained by selecting the above-mentioned single fiber weave degree and crimp characteristics. In general, focusing on the density that can be regarded as the reciprocal of bulk, the density of cushion material is 0.01 to

0.06 g / cm ³ is preferred, and 0.02 to 0.05 g / cm ³ is more preferred. If the density is less than 0.01 g / cm ³ , the structure is too loose and sufficient rebound cannot be obtained. On the other hand, if it exceeds 0.06 g Zcm ³ , the resilience is sufficient, but it is difficult to achieve the purpose of reducing the weight.

Another important point for cushioning material is how to fix the above matrix fibers as a structure. In other words, the cushioning material must be able to sufficiently withstand deformation under stress, and must be fixed so that it can quickly recover to its original shape when released from stress.

In the cushion material of the present invention, the matrix is fixed by a thermal fusion (thermobond) method of thermoplastic elastic fibers. According to this heat fusion, the desired fixing as described above is achieved, and in addition to the wet method using a liquid resin binder, there is an advantage that the working environment is better and the safety is higher. . Thermal fusion is achieved by using thermoplastic elastic fibers whose melting point is much lower than that of the inelastic crimped short fibers that make up the matrix, preferably by a melting point of at least 60 ° C. The details of the arrowhead will be described later.)

It should be noted that the matrix of the heat-resistant flame-retardant cushion material of the present invention is fixed by using thermoplastic elastic fibers which are not themselves flame-retardant. Nevertheless, the cushioning material is excellent in heat resistance and flame retardancy. This was achieved only by mixing and dispersing a flame-resistant crimped short arrowhead fiber with a residual weight of 35% or more by a flameless test method in a matrix consisting of an inelastic crimped short arrowhead fiber aggregate. can do. In other words, the matrix fiber and such a flame-resistant arrowhead fiber are heat-fixed by the thermoplastic elastic arrowhead fiber, so that they have both high flame retardancy, bulkiness, heat resistance and durability. It becomes cushion material.

Here, the residual rate by the flameless test method is measured as follows.

—Place an electric heater in a 50 cm cubic box, place 1 g of the sample in a basket at the center of the box so that the melt does not drip, and pyrolyze at 75 ° C for 4 minutes Perform processing. At that time, the temperature is measured with a thermocouple installed on the sample stage. The residual ratio is calculated from the weight change of the sample after pyrolysis.

The ratio of flame-resistant arrowhead fibers with a residual weight ratio of 35% or more according to the flameless test method to the inelastic crimped staple fiber, which is a matrix, is 0.1 Z1 to 1/1 (weight ratio). I prefer that there be. If this ratio exceeds 1/1, the bulkiness and durability of the cushion material decrease, and if the ratio is less than 0.1 / 1, the flame retardant effect is poor. The weight remaining Although a certain degree of flame retardant effect can be achieved by blending a large amount of flame-resistant fibers having a survival rate of less than 35%, the bulkiness and durability of the cushion material are considerably reduced.

As flame-resistant textiles having a weight retention rate of 35% or more, polyoxylonilittle fibers are pre-oxidized and pre-oxidized fibers (for example, trade names such as "Rastan" and "Pyromex"). (Commercially available), fully carbonized carbon fiber, bridged vinyl arrowhead fiber (for example, marketed under the trade name "Kynol"), and polybensimi dabul (PBI) fiber. Among them, pre-oxidized soy fiber is particularly preferred.

If the monofilament fiber size of the flame-resistant crimped short textile is too large, the number of constituent fibers is reduced and the flame resistance effect is reduced. Therefore, the denier is preferably 8 deniers or less, more preferably 5 deniers or less. However, if it is too small, the eb formation property deteriorates, so it is preferable to keep the denier at about 1 denier.

Preferred materials for the inelastic crimped staple fiber of the cushion material of the present invention include polyester fiber and aramid arrowhead fiber, and a combination of these fiber and the above flame-resistant fiber. Are described in DE3307449A1, GB21 83265 and GB21 52542. However, these combinations are only embodied in continuous yarn, such as spun yarn, and ultimately teach that they are useful for imparting flame retardancy in two-dimensional fabrics. As described above, nothing is taught about a flame-retardant cushioning material made of a three-dimensional fiber structure and having excellent bulkiness and durability. In the cushion material of the present invention, the thermoplastic elastic fiber is mixed in the matrix in which the flame-resistant crimped short fiber is mixed and dispersed in the non-elastic crimped short fiber, and the thermoplastic elastic fiber is mixed. At least a part of the entanglement point between the fiber and the inelastic crimped staple fiber and the flame-resistant crimped staple fiber is heat-sealed. The mixing ratio of the thermoplastic elastic fiber varies depending on the type of the thermoplastic elastic fiber used, but is preferably from 10 to 50% by weight of the total weight. If the mixing ratio is less than 10% by weight, the flame retardancy is good, but the number of fixing points for heat fusion is too small, and it is difficult to maintain the resilience of the cushioning material, resulting in poor durability. If the mixing ratio exceeds 50%, it is difficult to maintain the flame retardancy of the cushion material. In short, when the ratio of the thermoplastic elastic fiber to the total weight is 10 to 50% by weight, the heat fusion between the inelastic crimped short fiber and the flame-resistant crimped short fiber in the matrix is sufficient and the cut is made. It does not cause laminar separation in the thickness direction of the cushioning material, and the cushion has good repulsion and durability.

Here, the thermoplastic elastic fiber used to form the heat fixation point is a composite fiber formed of a thermoplastic elastomer and an inelastic polyester, and a matrix is used. Those having a melting point lower than that of the inelastic crimped short fibers by 60 ° C or more are preferably used. If the difference in melting point is less than 60 ° C, the thermoplastic elastic fiber deteriorates during the heat treatment, and the matrix arrowhead is likely to be adversely affected.

Further, it is preferable that the thermoplastic elastomer occupies at least 1/2 of the surface of the composite textile, and in terms of weight ratio, the thermoplastic elastomer and the non-elastic polyester are 30/70 to 100%. It is appropriate to be in the range 70/30.

The form of the composite fiber may be either a side-by-side type or a sheath-core type, but the latter is preferred. In the sheath-core type, inelastic polyester is the core, but this core may be concentric or eccentric. In particular, eccentric ones are more preferable because they exhibit coiled elastic crimps.

Examples of the thermoplastic elastomer include a polyurethane-based elastomer and a polyether polyester-based elastomer. Examples of the inelastic polyester include polyethylene terephthalate and polybutylene terephthalate, and polybutylene terephthalate having rubber elasticity is particularly preferable.

It should be noted that the thermoplastic elastic fiber should be considered not only from the melting point but also from the viewpoint of cushioning performance, and especially at the intersection with the flame-resistant crimped short fiber with little crimp. It is preferred that sticking points are formed. In other words, since the fixing points formed by the thermosetting of the thermoplastic elastic fibers are composed of the elastomer component, they can be greatly deformed according to the applied stress, and the stress is released. After that, it can be returned to its original form promptly. In addition, due to its excellent elongation and recovery properties, there is no breakage or residual strain due to repeated loading, and it has the function of minimizing the drop in cushioning performance due to the small crimp of the flame-resistant textile. I do. Therefore, it is preferable that the single fiber fineness of the thermoplastic elastic fiber is larger than the single fiber fineness of the flame resistant arrowhead. Preferred thermoplastic elastic fiber properties include elongation at break.

5 0 0% or more, 3 0 0% elongation stress 0. 6 kg Jour ² or less, and 3 is 0 0% elongation recovery ratio 6 0% or more. Can not and this to withstand large deformation is less than the breaking elongation is 5 0 0% and 3 0 the 0% elongation stress exceeds 0. 6 kgZ mm ² and this showing a smooth deformation stress is too high, Can not. In other words, comfortable cushioning cannot be provided. If the 300% elongation recovery rate is less than 60%, good deformation recovery cannot be expected after stress release.

That is, the cushioning material of the present invention is used to obtain a flame-resistant cushioning material capable of passing the FAA standard by mixing flame-resistant fibers into a matrix short textile. If the mixing amount of the matrix staple fiber is equal to or less than that of the matrix staple fiber, flame resistance is obtained due to the synergistic elastic repulsion effect of the crimp of the matrix staple fiber and the thermoplastic elastic fiber forming the fixing point. It has been completed based on the finding that the cushioning performance that does not hinder practical use can be maintained by compensating for the small crimp of the fiber.

The cushion material of the present invention has a substantially uniform structure composed entirely of the above-mentioned inelastic crimped short fiber aggregate, flame-resistant crimped short fiber and mature plastic fiber as described above. Or a two-layer structure consisting of an inner layer made of a fiber assembly and an outer layer surrounding the inner layer, and the outer layer is made of the above-described inelastic crimped short fiber assembly, It may be composed of crimped short fibers and thermoplastic elastic fibers. The inner layer of the latter two-layer structure may be made of the same material as the outer layer, but the outer layer is formed as described above. If the emphasis is placed on bulkiness and durability of the cushioning material as a whole, the inner layer is composed of only inelastic crimped short fibers and thermoplastic elastic fibers. This is preferred.

Here, as the material of the inelastic crimped short fiber constituting the inner layer, polyester fibers excellent in mechanical properties such as strength and modulus and crimping properties such as crimping property and crimp fastness are preferable. New Further, as the thermoplastic elastic fiber used for the inner layer, the same material as the above-mentioned outer layer is used. The amount of the thermoplastic elastic fiber is preferably 10 to 50% of the total weight of the inner layer from the viewpoint of bulkiness and durability as the cushion material.

Since the thermoplastic elastic fiber is mixed and dispersed in each of the inner layer and the outer layer, it is also firmly fixed at the joint surface between the inner layer and the outer layer, and the joint surface between the two layers is not clear. Therefore, the cushioning material has a separation strength in the thickness direction of 1.0 kg or more, and is excellent in durability. Here, the separation strength was tested after bonding the cushioning material and the reinforcing cloth with an adhesive in accordance with ASTM D 3574, and after standing for 24 hours under a pressure of 10 g Z cm ^2. It is measured at a half width of 25 discussions and a separation speed of 50 圆 Z minutes. The thickness and density of the outer layer of the two-layer cushion material can be selected as appropriate, but from the viewpoint of flame retardancy and surface abrasion fastness, the thickness is 3 to 10 mm, and the basis weight is 2. 0 0 to 500 g

Zm ² is preferred.

The heat-resistant and flame-retardant cushion material of the present invention uses inelastic crimped staple fibers as a matrix fabric, and mixes flame-resistant crimped staple fibers with a thermoplastic elastic fabric to obtain a thermoplastic fabric. At least the intertwining point between elastic fiber and inelastic crimped short fiber and Z or flame-resistant crimped short fiber It is manufactured by a method in which a part is heat-sealed and integrated. In order to produce a homogeneous and high-performance cushioning material in as short a process as possible, it is necessary to thoroughly knead the aggregate consisting of inelastic crimped short fibers, flame-resistant crimped short fibers and thermoplastic elastic fibers. However, it is preferable to perform treatment and fusion at a temperature lower than the melting point or decomposition temperature of the inelastic crimped short fiber and higher than the melting point of the thermoplastic elastic fiber by 20 to 60 ° C. If the processing temperature is too low, the polymer does not flow in a favorable state at the entanglement point and the bonding is insufficient, the number of heat fixation at the entangled portion of the short arrowhead fiber decreases, and the resilience of the cushion material decreases. If the processing temperature is too high, the thermoplastic elastic fiber will deteriorate due to the heat, and the physical properties of the heat fixation point will decrease.

The heat-resistant and flame-retardant cushion material having a two-layer structure is obtained by separately kneading the materials constituting the outer layer and the inner layer in the same manner as described above, surrounding the inner layer assembly with the outer layer assembly, and then integrating the two. Is heat-treated in the same manner as described above and fused and integrated.

The cushion material is molded into vehicle seats and other cushion products. To mold into a vehicle sheet, the mixed unheated aggregate is packed in a prescribed molding mold and then molded at the above heat treatment temperature or mixed and preheat fused at a temperature lower than the above prescribed heat treatment temperature. Then, it is pressed into a shape close to the shape of the molding mold, packed in the prescribed molding mold, and heat-treated at a predetermined temperature, or mixed, and heat-fixed at the above-mentioned heat treatment temperature. It is possible to adopt a method of cutting and molding simultaneously with bonding using an adhesive in a predetermined molding mold. In addition, a sliver method as disclosed in EP 0483386A1, disclosed in Japanese Patent Application Laid-Open No. 3-209091 It is also possible to adopt a blow molding method or the like.

Here, the term “vehicle sheet” refers to a “vehicle” sheet in a broad sense, and includes not only the seat sheets of automobiles and other land transportation but also the seat sheets of aircraft.

Hereinafter, the cushioning material of the present invention will be specifically described with reference to examples. In the examples, various characteristics of the fiber and the cushion material were measured by the following measuring methods.

(1) Fiber properties

(A) Fineness (denier), number of crimps (CN), and crimp ratio (CD) were measured in accordance with JIS 1015.

(π) Initial bulkiness and bulkiness under load

Bulkiness (cm ³ / gr) under a load of 0.5 grZcm ² and 10 gr / cm ² was measured in accordance with JIS 1097, respectively.

(2) Characteristics of cushioning material

(B) Density Measured according to JIS K6401.

(0) Rebound resilience Measured in accordance with JIS K 6401.

(C) Compression residual strain (50% and repeated 80,000 times)

It was measured in accordance with JIS K 6401.

(-) Air permeability Measured in accordance with JIS L 1079.

(E) FAA flame retardancy test Combustion test method adopted by FAA (Federal Aviation Administration Federal Aviation Administration) FAR (Federal Aviation Regulation), part 25 (25.853) (Airworthiness Standards, Transport Category Air Planes published June 1974, y US Department of Transportation). By the way, the FAA flame retardant test passed the standard, but the weight was reduced. The fraction is 10% or less, the combustion length bottom is 46 cm or less, and the combustion length back is 43 cm or less.

Example 1

A non-elastic crimped short fiber is a meta-aramid arrowhead fiber (Teijin Cornex® is used as a matrix, and a flame-resistant crimped short fiber has a weight retention rate of 4 based on the flameless test method. Select a pre-oxidized arrowhead fiber (“Raster”, 2 denier x 74 mm) made by preoxidizing 8% polyacrylonitrile fiber, and use it as a thermoplastic elastic fiber as shown below. Was used.

Tertiphthalic acid and isophthalic acid are polymerized with butylene glycol by mixing an acid component with 80 Z 20 (mol), and 38% by weight of the obtained polybutylene terephthalate is further added to polybutylene glycol (molecular weight). The block copolymerized polyether polyester elastomer was subjected to ripening reaction with 200% by weight of 200% to obtain a block copolymerized polyether polyester elastomer having an intrinsic viscosity of 1.0, a melting point of 155 and a melting point of 15.5%. elongation at break 1 5 0 0% for I Lum, 3 0 0? extension stress is 0. 3 kg / mm ^2, 3 0 0% elongation recovery rate was found to be 5% Ί.

This thermoplastic elastomer was used as a sheath, and polybutylene terephthalate was used as a core. The core Z sheath was spun by a conventional method so as to have a weight ratio of 50 to 50. This composite fiber is an eccentric sheath-core type composite fiber. The fiber was stretched 2.0 times, cut into 64 mm, and heat-treated with warm water at 95 to reduce shrinkage and develop crimp, dried, and then applied with an oil agent. The single-head arrowhead degree of the thermoplastic elastic fiber obtained here was 6 denier. 70% by weight of matrix arrowhead fiber ("Cornex": Tongue = 1: 0.2) and 30% by weight of the above-mentioned thermoplastic elastomer-short-weave fiber were mixed with a card to obtain a web. The web was overlaid, the thickness was 10 cm, the density was 0.0. 5 g / cm ³ was placed in a flat mold and heat-treated at 200 for 10 minutes to obtain a flat cushion material. Table 1 shows the performance when the value was changed at 13 denier X76 palace (Experiment Να1-3).

Example 2

In Example 1, Experiment Not 2, the experiment was performed in exactly the same manner as in Example 1 except that the ratio of Cornex II and Rastan® was changed out of 70% by weight of the matrix arrowhead fiber. Four and five cushion materials were obtained.

Example 3

Example 1, Experiment No. 2 The cushion material of experiment NOL 6 was obtained in exactly the same manner as in Example 1, except that the ratio of the elastic fiber to the total weight was changed.

Example 4

Example 1, Experiment No. α2, except that the heat treatment temperature was changed, was performed in exactly the same manner as in Example 1, and a cushion material of Experiment No. α7 was obtained.

Example 5

In Example 1, Experiment No.2, the flame-resistant crimped staple fibers having different weight retention ratios by the flameless test method (cross-linked phenolic arrowhead fiber "Rinol" ®, 3-denier X 70 mm, or cross-linked) Melamine-based textile "Bazofil" ®, 2.3 denier x 75 mm) Other than that, the operation was performed in exactly the same manner as in Example 1 to obtain cushion materials for Experiments Να8 and 9.

Example 6

In Example 1, a polyethylene terephthalate having the properties listed in Table 2 as a matrix fiber (維 Ρ

Τ) Textile (14 denier x 64 mm), polyethylene terephthalate (PET) obtained by copolymerizing 0.7% by weight of a phosphorus compound Textile fiber (13 denier x 51 mm) and polyester Table 2 shows the ratio of flame-resistant textiles to matrix fibers, using a hexaneterephthalate (PCT) textile (25 denier x 76 marshal). The cushion material was obtained in exactly the same manner as in Example 1, Experiment II α2, except for the changes shown in Fig. 2.

Example 7

As a matrix fiber, a meta-aramid fiber (Teijin Connex, 13 denier X 76 mm) having the properties described in Table 2 was used. Flame-resistant fibers and elastic arrowhead fibers were mixed with a matrix arrowhead fiber at the ratios shown in Table 2 Experiment No. α13 to obtain a web (cardiac component). On the other hand, a polyethylene phthalate fiber (14 denier X 64 mm, various characteristics described in Experiment No. α10) was used as a matrix, and the thermoplastic elastic fiber of Example 1 was used as a matrix. The cotton was mixed with a card at a weight ratio of 70: 30% to obtain a web (component (i)). Then, while completely surrounding the web of the で component, the web of the 、 component is placed in a flat mold so as to have a thickness of 1 Ocm, and matured at 200 for 15 minutes to form a flat plate. 2-layer cushion material (A component: outer layer, R component: inner layer) I got At this time, the thickness and the basis weight of the A component (outer layer) were changed, and cushion materials of Experiment No. α13 to 15 were obtained.

Example 8

In Example 7 and Experiments III and III, the matrix fiber of the Β component (inner layer) was mixed with poly (1,4) -dimethylcyclohexane terephthalate fiber (25 denier X76 bandages, various properties) Was the same as that described in Experiment 12), except that a two-layer cushion material of Experiment ΝαΝ6 was obtained.

table 1

(Ratio) is a comparative example

'"-" ""---- _ Run Να 1 2 3 4 5 6 7 8 9

(Ratio) Matrix Weaving “Ryamide Ryame F; ¹ Ryami Rami F Ryami Rami F Meta Ryramide Meta Ryramide

Denier 13 13 13 13 13 13 13 13 13 13

CN pcs / inch 6 8 14 8 8 8 8 8 8

16 20 30 20 20 20 20 20 20

Structure Initial bulkiness cmVgr 45 60 85 60 60 60 60 60 60

Bulk under load cmVgr 17 25 40 25 25 25 25 25

Flame-resistant fiber Rasin Rastin Raskun Rastin Rastin Rastin Rastin Kainol Bazofil

Flameless test method

Reconstruction ί¾ι ¥% 48 48 48 48 48 48 48 39 28 X

^{7 to} 7 ratio 1: 0.2 1: 0.2 1: 0.2 1: 0.3 1: 0.7 1: 0.2 1: 0.2 1: 0.2 1: 0.2

Elastic fiber s / cii compound S / C compound S / C compound S / C compound S / C compound S / C compound S / C compound S / C compound S / C compound

Occupied ° C 155 155 155 155 155 155 155 155 155 oo% of total% 30 30 30 30 30 15 30 30 30 Heat treatment temperature C 200 200 200 200 200 200 210 200 200 Density g / cm ³ 0.050 0.052 0.052 0.052 0.052 0.052 0.051 0.053 0.052 0.051

Rebound resilience on

% 55 ο Di U υο DO ΌΌ OO

50% compression set% 16.2 15.5 14.3 15.8 16.4 18.0 16.2 14.9 14.6

Compression 80,000 times

Residual strain% 8.9 7.6 6.1 8.0 9.2 9.1 8.3 7.3 7.5

Breathability cc / cm ² 120 122 120 105 98 110 125 122 118

• sec

Material F A ΑTest

Weight loss% 6.5 6.3 6.2 5.8 5.1 5.8 6.4 8.5 15.6

Combustion length bottom cm 22 22 21 20 16 22 22 36 46

Cook cm 39 40 38 38 35 38 40 42 48

Table 2

Industrial availability

The cushion material of the present invention does not require any harmful substances such as freon in the manufacturing process, and has sufficient air permeability even as a cushion material, so there is no fear of stuffiness. Absent. In addition, the cushioning properties are not too high in the initial hardness due to compression, and the rebound is large, and the rebound is increased almost in proportion to the amount of compression. Also, regarding the disposal issue that has been attracting attention these days, it is extremely easy to dispose of it by incineration, as there is no harmful gas generated by combustion like polyurethane. In addition, when compared with flame-retardant polyester, which has begun to be used for some aircraft airplanes, such advantages as the above-mentioned cushion characteristics and easy disposal can be maintained. Needless to say, there is no need for high density (more than 0.060 g / cm ³ ), which is the biggest drawback of flame-retardant polyurethane, and needs have been increasing in recent years. Meets weight reduction requirements. In particular, it has optimal characteristics as a cushion body for various vehicle seats.

Recently, a polyester fiber has been used as a matrix, and the binder fiber used for the thermoplastic elastomer has been melted, and at least a part of the entangled points has been fused and fixed. Cations have been proposed, and although these cushioning materials of fiber structure are useful as general cushioning materials, they are not suitable in terms of flame retardancy, which has been particularly demanded recently. Completely, in this sense, the present invention is, for the first time, a comfortable textile fabric cushioning material with sufficient flame retardancy.

In addition, the structure with high added value of flame retardance in manufacturing. It is also a great advantage that a uniform cushioning material can be obtained in a simple and short process simply by heat-treating a web made of short fibers while being a body.

Therefore, the cushion material of the present invention is excellent in flame retardancy, cushioning property, durability, and form stability, has high air permeability, does not easily become stuffy, and does not easily generate unevenness in processing, and Diversity is easy. Therefore, it can be used not only for general furniture and bedding that require flame retardancy, but also for hospitals, nursing home furniture, bedding, vehicle seat cushions, especially subways, ships, and Shinkansen trains. Wide-ranging items such as vehicle seats, airplane sheets, racing car sheets, fillings requiring flame retardancy, and miscellaneous goods are conceivable.

In particular, it maintains cushioning and is harder in flame retardancy, for example, by using a 108 ° C burner for 102 minutes at a distance of 102 ° C, as in the FAA flame retardant test for aircraft sheets. It is very effective for flame retardant requirements such as flame contact.

Claims

The scope of the claims

1. In a matrix consisting of an inelastic crimped short fiber aggregate, a flame-resistant crimped short fiber having a residual weight of 35% or more by a flameless test method and a thermoplastic elastic fiber A heat-resistant and flame-retardant cushioning material characterized in that at least a part of the entanglement point between the thermoplastic elastic fiber and another textile is heat-sealed.

2. Flame-resistant crimped short fibers selected from fibers pre-oxidized from acrylonitrile polymer fibers, carbon fibers, cross-linked phenolic fibers, and polybenzimidazole fibers. The heat-resistant and flame-retardant cushion material according to claim 1.

3. The heat-resistant and flame-retardant cushion material according to claim 1, wherein the single-woven fiber size of the flame-resistant crimped short fibers is 8 denier or less.

4. The heat-resistant and flame-retardant cushion material according to any one of claims 1 to 3, wherein the single-filament fineness of the flame-resistant crimped short textile is smaller than the single-filament fineness of the thermoplastic elastic fiber.

5. The ratio of flame resistant crimped short fibers to inelastic crimped short fibers is 0.1

The heat-resistant and flame-retardant cushion material according to any one of claims 1 to 4, which has a weight ratio of 1: 1 to 1: 1.

6. The heat-resistant and flame-retardant cushion material according to any one of claims 1 to 5, wherein the thermoplastic elastic fiber accounts for 10 to 50% of the total weight.

7. The heat-resistant and flame-retardant cushion material according to any one of claims 1 to 6, wherein the inelastic crimped staple fiber is selected from a polyester fiber or an aramid fiber.

8. Inelastic crimped filaments odometer is 4-3 0 0 denier staple fiber, initial bulk properties 4 0~ 1 2 0 cm V g . 1 0 gr / cm under ² load bulk properties 1 5 The heat-resistant and flame-retardant cushion material according to any one of claims 1 to 7, which has a pressure of from 50 to 50 cmVg.

9. The heat-resistant and flame-retardant cushion material according to any one of claims 1 to 8, wherein the separation strength in the thickness direction is 1.0 kg or more.

5 10. In a matrix consisting of an inelastic crimped short fiber aggregate, a flame-resistant crimped short fiber having a weight retention rate of 35% or more by a flameless test method, and a thermoplastic elastic fiber Is formed by molding a heat-resistant and flame-retardant cushion material in which at least a part of the entanglement point between the thermoplastic elastic fiber and another fiber is heat-sealed. G. 0 1 1. From flame-resistant crimped short fibers made from acrylonitrile polymer fibers, pre-oxidized arrowheads, carbon fibers, cross-linked phenolic fibers and polybenzimidazole arrowheads. The vehicle sheet according to claim 10, which is selected.

12. The vehicle sheet according to claim 10 or 11, wherein the single arrowhead weave degree of the flame-resistant crimped short weave is 5 at 8 deniers or less.

13. The vehicle sheet according to any one of claims 10 to 12, wherein a single-woven fiber size of the flame-resistant crimped short arrowhead fiber is smaller than a single-fiber arrowheadness of the mature fiber.

14. The vehicle according to any one of claims 12 to 13, wherein the ratio of the flame-resistant crimped staple fiber to the inelastic crimped staple fiber is 0.1: 1 to 1: 1 (weight ratio). Sheet.

15. The vehicle sheet according to any one of claims 10 to 14, wherein the thermoplastic elastic fiber has a total weight of 10 to 50 °.

16. The inelastic crimped short arrowhead fiber according to any one of claims 10 to 15, wherein the short arrowhead fiber is selected from polyester fibers or arami fibers. Vehicle seat.

1 7. Inelastic crimped staple fibers have a single arrow weave degree of 4 to 300 denier and an initial bulk of 40 to 120 cm ³ / g 10 gr / cm ² bulk under load force 1 5 ~ 5 0 cm ³ / g and a claim 1 0-1 6 vehicle sheet for placing serial to either.

18. The vehicle sheet according to any one of claims 10 to 17, which is an aircraft sheet.

19. The vehicle seat according to any one of claims 10 to 17, which is a racing car seat.

20. It has a two-layer structure consisting of an inner layer composed of an arrowhead fiber assembly and an outer layer surrounding the inner layer. The outer layer is free from flames in a matrix composed of an inelastic crimped short arrowhead fiber assembly. Flame-resistant crimped staple fibers having a weight retention rate of 35% or more according to the test method are mixed and dispersed with a thermoplastic elastic fiber, and at least one entanglement point between the thermoplastic elastic arrowhead fiber and other fibers. A heat-resistant and flame-retardant cushioning material characterized in that its parts are heat-sealed.

2 1. Outer layer of flame-resistant crimped staple fiber is pre-oxydized acrylonitrile polymer fiber, carbon fiber, cross-linked phenolic arrowhead and polyvenzimidazo arrowhead. The heat-resistant and flame-retardant cushion material according to claim 20, which is selected from the group consisting of:

22. The heat-resistant and flame-retardant cushion material according to claim 20, wherein the fineness of the single fiber of the flame-resistant crimped staple fiber in the outer layer is 8 denier or less.

23. The ratio of the flame-resistant crimped staple fibers to the inelastic crimped short fibers in the outer layer is 0.1: 1 to 1: 1 (weight ratio). 22. The heat-resistant and flame-retardant cushion material according to any of 2.

24. The heat-resistant and flame-retardant cushion material according to any one of claims 20 to 23, wherein the thermoplastic elastic fiber of the outer layer accounts for 10 to 50% of the total weight of the outer layer.

25. The heat-resistant and flame-retardant cushion material according to any one of claims 20 to 24, wherein the inelastic crimped staple fiber of the outer layer is selected from a polyester fiber or an aramid fiber.

26. The heat-resistant flame retardant according to any one of claims ²⁰ to 25, wherein the outer layer has a thickness of 3 to 1.0 mm and a basis weight of 200 to 500 g nom2. Cushioning material.

27. The heat-resistant and flame-retardant cushion material according to any one of claims 20 to 26, wherein the inner layer is made of a polyester crimped short fiber or a fiber mixture containing the same as a main component.

28. The heat-resistant and flame-retardant cushion according to any one of claims 20 to 27, wherein thermoplastic elastic arrowhead fibers are mixed and dispersed not only in the outer layer but also in the inner layer, and both layers are adhered to each other. N

29. It has a two-layer structure consisting of an inner layer composed of a fiber assembly and an outer layer surrounding the inner layer, and the outer layer is free from the matrix composed of the inelastic crimped short arrow fiber assembly. A flame-resistant crimped short fiber with a residual weight ratio of 35% or more according to the flame test method and a thermoplastic elastic fiber are mixed and dispersed, and the number of entanglement points between the thermoplastic elastic fiber and other fibers is small. A vehicle sheet made of heat-resistant and flame-retardant cushion material, both of which are partially fixed by heat melting.

30. Flame-resistant crimped short fibers made of pre-oxidized acrylonitrile polymer fiber, carbon fiber, cross-linked phenol The vehicle seat according to claim 29, wherein the vehicle seat is selected from a system fiber and a polybenzimidabour fiber.

31. The vehicle sheet according to claim 29, wherein the outer layer has a single-weave degree of weave of the flame-resistant crimped short weave of 8 denier or less.

32. The vehicle according to any one of claims 29 to 31, wherein the ratio of the flame-resistant crimped short fibers to the inelastic crimped short fibers in the outer layer is 0.1: 1 to 1: 1 (weight ratio). Sheet.

33. The vehicle sheet according to any one of claims 29 to 32, wherein the thermoplastic elastic fiber in the outer layer accounts for 10 to 50% of the weight of the outer layer.

34. The vehicle seat according to any one of claims 29 to 33, wherein the non-elastic crimped short fiber of the outer layer is selected from polyester fiber or aramid arrowhead fiber.

3 5. A thickness. 3 to 1 0 mm in outer layer, vehicle sheet according to any one the basis weight of 2 0 0 ~ 5 0 0 g Zm 2 a is claim 2 9-3 4.

36. The vehicle sheet according to any one of claims 29 to 35, wherein the inner layer is made of a polyester crimped short fiber or a mixture of arrowhead fibers mainly containing the same.

37. The vehicle sheet according to any one of claims 29 to 36, wherein thermoplastic elastic arrowhead fibers are mixed and dispersed not only in the outer layer but also in the inner layer, and both layers are adhered to each other.

38. The vehicle sheet according to any one of claims 29 to 37, which is an aircraft sheet.

39. The vehicle seat according to any one of claims 29 to 37, which is a racing car seat.