WO2006008958A1

WO2006008958A1 - Flame-retardant synthetic fiber, flame-retardant fiber composite, and upholstered furniture product made with flame-retardant fiber composite

Info

Publication number: WO2006008958A1
Application number: PCT/JP2005/012383
Authority: WO
Inventors: Wataru Mio; Masahiko Mihoichi
Original assignee: Kaneka Corporation
Priority date: 2004-07-15
Filing date: 2005-07-05
Publication date: 2006-01-26
Also published as: JPWO2006008958A1

Abstract

Highly flame-retardant synthetic fibers which have been flame-retarded with a flame retardant to a high degree, has extremely high carbonizability, and is suitable for use in textile products used in, e.g., beds and furniture required to have a high degree of flame retardancy; and a flame-retardant composite comprising the fibers. The flame-retardant synthetic fibers comprise 100 parts by weight of a polymer having a halogen atom content of 17 wt.% or higher and 5-50 parts by weight of kaolin. The flame-retardant fiber composite is characterized by comprising at least 40 parts by weight of the flame-retardant synthetic fibers (A) and up to 60 parts by weight of at least one kind of fibers (B) of natural fibers and/or synthetic fibers.

Description

Specification

Flame retardant synthetic fibers, flame retardant fiber composites and upholstered furniture products using flame retardant fiber composites

Technical field

[0001] The present invention is suitable for textile products used for bedding such as mattresses that require high flame retardance and furniture such as chairs and sofas that have extremely high carbonization ability that is highly flame retardant with flame retardants. A flame retardant synthetic fiber having a high degree of flame retardancy, a flame retardant fiber composite comprising the flame retardant synthetic fiber and another fiber, and the flame retardant fiber composite And non-woven fabrics, and upholstered furniture products using them.

Background art

[0002] In recent years, the demand for ensuring the safety of clothing, food and housing has increased, and the need for flame retardant materials has increased. Under such circumstances, there is a strong demand for imparting flame retardancy to materials used for bedding and furniture. In these textile products, flammable materials such as cotton and urethane foam are used for comfort during use. It is important to prevent interference. In addition, the flameproof material must not impair the comfort and design of bedding and furniture!

[0003] Various flame retardant fibers and disaster prevention agents have been studied in the past, but no one has yet emerged that combines this high level of flame retardancy with the requirements of products such as bedding and furniture.

[0004] For example, there is a technique called so-called post-processing disaster prevention, which applies a disaster prevention agent to cotton cloth. Issues such as uniform adhesion of the disaster prevention agent, hardening of the cloth due to adhesion, detachment due to washing, safety, etc. .

[0005] In addition, when polyester, which is an inexpensive material, is used, polyester cannot become a carbonizing component. Therefore, when forced combustion is performed, holes are formed by melting and combustion, and the structure can be maintained. It was impossible to do so, and the fire resistance to prevent the flame and cotton used in the above-mentioned bedding and furniture was completely inadequate.

[0006] In addition, fabrics made from heat-resistant fibers have excellent flame retardancy, but are extremely expensive. Further, the fabrics are designed due to problems in processability at the time of fiber opening, poor hygroscopicity and touch, and poor dyeability. High quality color There is also a problem that it is difficult to get a handle.

[0007] As a material having improved texture, moisture absorption, and tactile sensation required as general characteristics, as well as a material having stable flame retardancy, it has improved the defects of these furniture and bedding materials. A flame retardant fiber composite comprising a highly flame retardant halogen-containing fiber to which a large amount of a flame retardant is added and other fibers not flame retardant (Patent Document 1 Japanese Patent Laid-Open No. 61-89339) ) Has been proposed. In addition, it is a highly flame-retardant fiber composite (Patent Document 2 JP-A-8-218259) that can be used for work clothes by mixing a small amount of heat-resistant fiber. Although there is a description that it has flame retardancy, organic heat-resistant fibers are generally colored, the whiteness of the fabric is insufficient, there is also a problem in coloring due to dyeing, and there is a problem in design properties Flame retardant fiber composite It was a body. In addition, a flame retardant nonwoven fabric (Patent Document 3WO03Z023108) having a bulkiness such as a fiber which is inherently flame retardant and a halogen-containing fiber cable has been proposed. If these fibers are not used in combination, high flame retardancy cannot be obtained, the product manufacturing process becomes complicated, and organic heat-resistant fibers and fibers that are inherently flame retardant are generally expensive. There is a problem that it is disadvantageous in terms of cost.

Disclosure of the invention

Problems to be solved by the invention

[0008] The present invention provides a single issue of a fiber product used for furniture, bedding, etc. that has been difficult to solve with conventional flame retardant fibers, that is, good workability, texture, and touch, and has good design properties. It was made in order to make it possible to manufacture at low cost with raw materials, and it was made in order to obtain flame retardant fiber composites and upholstered furniture products that can be used for the above applications. Means for solving the problem

[0009] As a result of intensive studies to solve the above problems, the present inventors have incorporated a flame retardant containing kaolin as a main component into a halogen-containing synthetic fiber, thereby improving workability and texture. A flame-retardant synthetic fiber capable of obtaining a textile product used in furniture, bedding, etc. that has a flame retardant property that can withstand a long-term flame that has good tactile feel and that does not impair the designability is obtained at a low cost. I found. In addition, the present inventors have found that processability and price problems, which were problems when using heat-resistant fibers alone, can be improved, and have completed the present invention.

That is, the present invention relates to 100 parts by weight of a polymer containing 17% by weight or more of halogen atoms. The present invention relates to a flame retardant synthetic fiber containing 5 to 50 parts by weight of kaolin. The flame retardant synthetic fiber (A) is 40 parts by weight or more and at least one kind of natural fiber and Z or chemical fiber (B) 60 parts by weight or less. The present invention relates to upholstered furniture products using composites and flame retardant fiber composites. Furthermore, the present invention relates to a nonwoven fabric comprising the flame retardant fiber composite, particularly a nonwoven fabric for flame shielding barrier, and upholstered furniture products using these.

The invention's effect

[0011] The flame-retardant synthetic fiber of the present invention, a flame-retardant composite comprising the same, and upholstered furniture using the same, the furniture product has a texture, tactile sensation,? It is possible to provide a textile product having high flame retardancy that is excellent in design such as appearance and processability and can withstand a long flame.

BEST MODE FOR CARRYING OUT THE INVENTION

[0012] The flame retardant synthetic fiber (A) of the present invention contains a polymer containing 17 wt% or more of halogen in a total of 5 to 50 parts by weight of kaolin with respect to the copolymer.

[0013] The preferable lower limit of the halogen content in the polymer containing 17% by weight or more of the halogen is 20% by weight, further 26% by weight, the upper limit is 86% by weight, further 73% by weight, and 48% by weight. %. When the halogen content is 17% by weight or more, it is possible to make the fiber flame retardant, which is preferable. The upper limit of the halogen content is 86%, which is the halogen content of the homopolymer of vinylidene odoride, and this value is the upper limit of the halogen content. In order to obtain a halogen content higher than this, it is necessary to increase the number of halogen atoms in the monomer, which is not technically practical.

[0014] Examples of the polymer containing 17 wt% or more of halogen as described above include, for example, a polymer of a monomer containing halogen, a monomer containing the halogen, and a monomer containing no halogen. No copolymer, no halogen-containing polymer and no halogen!力 Power that includes a mixture of a polymer, or a monomer or polymer that does not contain a halogen, or a halogen-containing polymer into which a halogen is introduced after polymerization, but is not limited thereto. .

[0015] Specific examples of such a polymer containing 17% by weight or more of halogen include, for example, halogen-containing bulu-based monomers such as salt vinyl, salt vinylidene, vinyl bromide and vinyl bromide. Homomeric homopolymers or two or more copolymers; acrylonitrile-salt-bule, talin-tolyl monosalt-biuridene, acrylonitrile monobromide butyl, acrylonitrile monosalt-bi-l monosalt Vinylidene, acrylonitrile monosalt-bulu monobromide, acrylonitrile — copolymers of acrylonitrile with halogen-containing vinyl monomers such as salt-vinylidene monobromide; salt-vinyl, salt-vinylidene, Copolymers of one or more halogen-containing vinyl monomers such as vinyl bromide and vinylidene bromide with acrylonitrile and vinyl monomers copolymerizable therewith; halogen in acrylonitrile homopolymer A polymer obtained by adding and polymerizing a compound containing a compound; a force including, for example, a halogen-containing polyester, but is not limited thereto. In addition, the above homopolymers and copolymers may be appropriately mixed and used.

[0016] Examples of the copolymerizable bur monomer include acrylic acid, its ester, methacrylic acid, its ester, acrylamide, methacrylamide, vinyl acetate, butyl sulfonic acid, its salt, methallyl sulfonic acid, Examples thereof include salts thereof, styrenesulfonic acid, salts thereof, 2-acrylamido-2-methylsulfonic acid, salts thereof, and the like, and one or more of them are used.

[0017] Polymer power containing 17% by weight or more of said halogen: 30 to 70 parts by weight of acrylonitrile, 70 to 30 parts by weight of halogen-containing vinyl monomer, and 0 to 10 parts by weight of vinyl monomer copolymerizable therewith , Preferably 40 to 60 parts by weight of acrylonitrile, 60 to 40 parts by weight of a halogen-containing butyl monomer and 0 to 10 parts by weight of a vinyl monomer copolymerizable therewith, The obtained fiber has a desired performance (strength, flame retardancy, dyeability, etc.) and is particularly preferable because it has a texture of acrylic fiber. In addition, it is preferable that at least one of the copolymerizable beryl monomers is a sulfonic acid group-containing beure monomer, since the colorability is improved.

[0018] Specific examples of the copolymer containing the halogen-containing bur monomer and a unit from acrylonitrile include, for example, a copolymer comprising 50 parts of chlor chloride, 49 parts of acrylonitrile, and 1 part of sodium styrenesulfonate, A copolymer consisting of 42.5 parts of salt vinylidene, 55 parts of acrylonitrile, sodium styrene sulfonate 1. 5 parts, 41 parts of salt vinylidene, 56 parts of acrylonitrile, 2-sodium 2-acrylamido-2-methylsulfonate There are 3 parts. [0019] The kaolin used in the present invention is used to maintain the fiber form during combustion, and is a naturally occurring clay containing silicon dioxide, alumina, and water as main components! / RU Since kaolin is a mineral produced from nature, the composition ratio of the main component differs depending on the production area, but the effect in the present invention does not change greatly. In kaolin, the ability to contain water in its components As a product, there are water-containing products that remain in the form of water, and baked products that do not contain water. An effective water-containing product is preferred for the purpose of enhancing the flame-retardant effect. Further, the average particle size of the kaolin is 2 m or less in order to avoid troubles such as nozzle clogging in the production process of a fiber obtained by adding kaolin to a halogen-containing polymer, and to improve the strength of the fiber. Point power is preferable. The reason why kaolin exerts the effect of maintaining the fiber shape during combustion is not clear, but kaolin is a plate-like crystal, so unlike kaolin, it becomes the nucleus of the carbonized film formed during combustion, and therefore the fiber shape. This is thought to have an effect of maintaining For this reason, when using conventional flame retardant fibers for fabrics, the effect of carbonization while maintaining the fiber form during combustion is weak, and the carbonized film of the fabric becomes thin, or the fabric has holes. When the flame-retardant synthetic fiber (A) of the invention is used, the effect of carbonization is maintained while maintaining the fiber form, carbonization can be performed while maintaining the fiber form during combustion, and the carbonized film of the fabric becomes thin. Or the defect that a hole is opened in the fabric is eliminated.

[0020] Roh, 5-50 parts by weight ratio of kaolin with respect to polymer containing androgenic 17 weight ^_0/0 or more, preferably 10 to 45 parts by weight, more preferably 15 to 40 parts by weight. If the amount is less than 5 parts by weight, the carbonization power is poor and it is difficult to maintain the fiber form during combustion. On the other hand, if the amount exceeds 50 parts by weight, nozzle clogging during fiber production and fiber properties (strength, elongation, etc.) will decrease, causing problems in the production and quality of flame-retardant acrylic fibers. I don't like it.

In the present invention, as long as the amount of kaolin with respect to the polymer containing 17% by weight or more of halogen is maintained at 5 to 49 parts by weight, it may be used in combination with other flame retardants.

[0022] Other flame retardants that can be used in combination with the kaolin include, for example, antimony oxide (Sb 2 O 3, Sb 2 O 3, Sb 2 O 3, etc.), antimonic acid and its salts, oxychloride Sb compounds such as inorganic antimony compounds such as antimony, halogen compounds such as hexabromobenzene, hexacyclodicyclohexane, chlorinated paraffin, halogen-containing phosphorus compounds such as tris (2,3-dichloropropyl) phosphate, polyphosphoric acid P-based compounds such as ammonium and dibutylaminophosphate, Mg-based compounds such as magnesium oxide, magnesium hydroxide, and magnesium carbonate, stannic oxide, metastannic acid, stannic oxyhalide, and stannous hydroxide Sn compounds such as tin tetrachloride, ZnSnO, ZnSn (OH), acids

3 6

Zn compounds such as zinc bromide and zinc borate, Mo compounds such as molybdenum oxide, Ti compounds such as acid titanium and barium titanate, N compounds such as melamine sulfate and guanidine sulfamate, Examples include A1 compounds such as aluminum hydroxide, Zr compounds such as zirconium oxide, and glass compounds such as low-melting glass and water glass. In addition, composite compounds such as magnesium stannate, zirconium stannate, zinc stannate, and zinc hydroxystannate may be used. The amount of the other flame retardant used is preferably 1 part by weight or more and 10 parts by weight or less based on the polymer containing 17% by weight or more of halogen. Among these flame retardants, Sb compounds exhibit a flame retardant effect in the gas phase system, and therefore exhibit higher flame retardancy when the flame retardant synthetic fiber (A) of the present invention is combined with other fibers. Then!

[0023] The flame-retardant synthetic fiber (A) of the present invention can be appropriately selected depending on the method of use, whether it is a short fiber or a long fiber. For example, it can be combined with other natural fibers and organic fibers. For calorie, approximating the fiber to be combined is preferred. Other natural fibers and chemical fibers used for textile products use: 1.7 to 12dtex, cut length 38 to 128mm I prefer fiber.

[0024] The reason why the flame retardant synthetic fiber (A) of the present invention exhibits excellent flame retardancy is that a flame retardant containing kaolin as a main component with respect to 100 parts by weight of the polymer containing 17% by weight or more of the halogen is used. Fiber (A) containing 5 to 50 parts by weight is burned by other fire source flames, but kaolin and unburned carbon in the plate-like structure remain in the fiber form as ash after combustion, so it is burned down and disintegrated. This is to maintain the form of the fabric.

[0025] The flame retardant synthetic fiber (A) of the present invention may contain an antistatic agent, a thermal coloring inhibitor, a light fastness improver, a whiteness improver, a devitrification preventive agent and the like as necessary. May be. [0026] The natural fiber and Z or chemical fiber (B) used in the present invention are for imparting excellent texture, touch, design, product strength, washing resistance and durability to the flame retardant fabric of the present invention. In addition, it is a component that improves workability when using a flame-retardant nonwoven fabric for bedding and furniture.

[0027] Specific examples of the natural fibers include plant fibers such as cotton and hemp, animal fibers such as wool, camel hair, goats, and silk, and specific examples of silk fibers. For example, recycled fiber such as viscose rayon fiber and cupra fiber, semi-synthetic fiber such as acetate fiber, or synthetic fiber such as nylon fiber, polyester fiber, polyester-based low melting point binder fiber, acrylic fiber, etc. V, not limited to. These natural fibers and chemical fibers may be used alone with the halogen-containing synthetic fiber (A). Two or more kinds of these natural fibers and chemical fibers may be used with the halogen-containing synthetic fiber (A).

[0028] Here, a melt is generated in the polyester-based fiber, and the carbonized film formed by the flame-retardant nonwoven fabric becomes stronger by covering the flame-retardant nonwoven fabric, and even when exposed to intense flames for a long time. It is possible to provide flame barrier performance that prevents flames on cotton and urethane foam used for bedding and furniture, easy to obtain bulkiness when processed into non-woven fabric, and for opening machines (cards). The strength problem of the halogen-containing synthetic fiber is also preferable because it reduces the damage to the fiber. Further, when a non-woven fabric is used, it is preferable to use a polyester-based low melting point binder fiber from the viewpoint that a hot melt bonding method can be used and processing is easy. The polyester-based low-melting-point binder fiber may be a low-melting-point polyester single-type fiber, or a parallel-type or core-sheath-type composite fiber such as polyester Z low-melting-point polypropylene, low-melting-point polyethylene, or low-melting-point polyester. Generally, the melting point of low-melting polyester is approximately 110 to 200 ° C, the melting point of low-melting polypropylene is approximately 140 to 160 ° C, and the melting point of low-melting polyethylene is approximately 95 to 130 ° C. There is no particular limitation as long as it has melting adhesive ability at about ° C.

In the present invention, the halogen-containing fiber (A) is 40 parts by weight or more and the natural fiber and Z or chemical fiber (B) is 60 parts by weight or less. Although they are manufactured, their mixing ratio is determined by the water-absorbing property, texture, moisture-absorbing property, tactile sensation, design properties, It is determined according to quality such as washing resistance and durability. Generally, halogen-containing fiber (A) 95-40 layers The total amount is 100 parts by weight, preferably 90-60 parts by weight, natural fiber and Z or chemical fiber (B) 5-60 parts by weight, preferably 10-40 parts by weight. From the viewpoint of flame retardancy, natural fiber and Z or chemical fiber (B) are not required, but it gives water absorbency, texture, moisture absorption, touch, design, product strength, wash resistance, durability, and other qualities. From the standpoint of processing, the ability to pass through the card when processing the fiber into a fiber product and the strength of the web sliver strength Add 5 parts by weight, preferably 10 parts by weight of natural fiber and Z or chemical fiber (B) It is preferable to do this. In addition, when the hot melt bonding method is selected during the production of the nonwoven fabric, it is preferable that at least 10 parts by weight of polyester-based low-melting-point binder fibers are included as natural fibers and Z or chemical fibers (B).

[0030] When the amount of the halogen-containing fiber (A) is less than 40 parts by weight, a carbonized film for preventing flames from being applied to cotton and urethane foam used for bedding and furniture when exposed to intense flames for a long time. Insufficient formation and poor fire resistance.

[0031] The flame retardant fiber composite of the present invention exhibits excellent flame retardancy because the flame retardant containing kaolin as a main component is added in an amount of 6 to 50 with respect to 100 parts by weight of the polymer containing 17% by weight or more of the halogen. Fiber (A) containing parts by weight is burned by other fire source flames, but after burning, the power of the plate-like structure and unburned carbon remain in the fiber as ash, so it will not burn out and collapse. This is to maintain the fiber form.

[0032] The flame retardant fiber composite of the present invention is a composite of the fibers (A) and (B) as described above, a fabric knitted fabric, a fabric such as a nonwoven fabric, a collection of fibers such as a sliver and a web, and spinning. It is of a form such as a string or a string such as a yarn or a mixed yarn'twisted yarn, a braided string, a braided string or the like

[0033] The term "combined" refers to obtaining a fabric containing fibers (A) and (B) by various methods and containing them in a predetermined ratio, and the blending, spinning, twisting, weaving, and knitting stages. It means to combine each fiber and thread.

[0034] The flame retardant fiber composite of the present invention is suitably used as a nonwoven fabric for a flame shielding barrier. The flame-shielding barrier here means that when the flame-retardant nonwoven fabric is exposed to flame, the flame-retardant nonwoven fabric is carbonized while maintaining the fiber form to shield the flame, and the flame moves to the opposite side. Specifically, surface fabrics such as mattresses and upholstered furniture and urethane foam that is an internal structure. By sandwiching the flame-retardant non-woven fabric of the present invention between the stuffed cotton and the like, it is possible to prevent ignition of the internal structure in the event of a fire and to prevent damage to a minimum. Non-woven fabric production methods such as general thermal bond method, chemical bond method, water jet method, needle punch method, stitch bond method, etc. can be used as a method for producing a flame retardant nonwoven fabric. It is created by blending the fibers, opening the card with a card, creating a web, and applying the web to a nonwoven fabric production device. In view of the simplicity of the apparatus, if a one-punch punch method or polyester-based low-melting-point binder fiber is used, the force generally produced by the thermal bond method is not limited to these methods.

[0035] The flame retardant fiber composite of the present invention may contain an antistatic agent, a thermal coloring inhibitor, a light fastness improver, a whiteness improver, a devitrification preventive agent and the like as necessary.

[0036] The flame retardant fiber composite of the present invention thus obtained has a desired flame retardancy,

It has excellent properties such as touch, hygroscopicity and design.

[0037] When a fiber product is produced using the flame retardant fiber composite of the present invention, the flame retardant fiber composite of the present invention has excellent characteristics, that is, excellent flame retardancy, texture, touch, and hygroscopicity. A fiber product having excellent characteristics such as design properties can be obtained.

[0038] The flame retardant fiber composite is required to have a high degree of flame retardancy and to have excellent general fiber characteristics such as texture, moisture absorption, touch, and design. Furniture with design

It is used for applications such as bedding.

[0039] Furthermore, the upholstered furniture of the present invention relates to bedding such as pineapple, chairs, sofas, vehicle seats, and the like upholstered by a flame-retardant fiber composite.

[0040] As the mattress, for example, a pocket coil mattress in which a metal coil is used, a box coil mattress, or a mattress in which an insulator in which styrene or urethane resin is foamed is used is used. is there. Since the flame retardancy by the flame retardant composite used in the present invention is exhibited, it is possible to prevent the spread of the fire to the structure inside the mattress. At the same time, it is possible to obtain a mattress with an excellent texture and feel.

[0041] On the other hand, as a chair, a stool, a bench, a side chair, an arm used indoors. Car seats, lounge chairs, sofas, seat units (sectional chairs, separate chairs), rocking chairs, folding chairs, stacking chairs, swivel chairs, or automobile seats, seats for ships, etc. Aircraft seats, train seats, etc. can be mentioned, but even in these cases, it is possible to obtain upholstered products that have the function of preventing the spread of fire inside as well as the appearance and feel that are required for ordinary furniture.

[0042] In addition, for mattresses and chairs using low-resilience urethane foam with pressure dispersion function represented by Tempur World material (Tempur World, Inc.), ordinary styrene and urethane are used. It is extremely flammable compared to mattresses and chairs that use foamed foam material, but the flame retardant composite used in the present invention demonstrates the flameproofness, It can prevent the spread of flame retardant foam, which is the internal structure of mattresses and chairs.

[0043] As a method of using the flame retardant fiber composite of the present invention for upholstered furniture products, the surface fabric may be used in the form of woven fabric or knit, or the surface fabric and internal structure such as urethane foam. Or it may be sandwiched between stuffed cotton in the form of woven fabric, knit, or nonwoven fabric. When used for the surface fabric, the fabric made of the flame retardant fiber composite of the present invention may be used instead of the conventional surface fabric. Further, when a woven fabric or a knit is sandwiched between the surface fabric and the internal structure, the surface fabric may be sandwiched in a manner that two sheets are stacked, or the internal structure is woven of the flame-retardant fiber composite of the present invention. It may be covered with cloth or knit. When the fabric is sandwiched between the surface fabric and the internal structure as a flame shielding barrier cloth, the flame retardant fiber of the present invention must be disposed on the entire internal structure, and at least the portion in contact with the surface fabric outside the internal structure. A non-woven fabric made of a composite is covered, and the surface fabric is stretched over it.

[0044] The flame retardant fiber composite of the present invention is a composite of halogen-containing synthetic fiber (A), natural fiber, and / or chemical fiber (B), and is a fabric such as a woven fabric or a non-woven fabric, a sliver or a web. Of fibers such as spun yarns and combined yarns such as twisted yarns, string-like items such as braids and braids.

[0045] The term "combined" refers to obtaining a fabric containing fibers (A) and (B) by various methods and containing them in a predetermined ratio, and the blending, spinning, twisting, weaving, and knitting stages. And that's it It means combining these fibers and yarns.

[0046] The flame retardant fiber composite usable in the present invention is suitably used as a nonwoven fabric for a flame shielding barrier. The flame-shielding barrier here means that when the flame-retardant nonwoven fabric is exposed to flame, the flame-retardant nonwoven fabric carbonizes while maintaining the fiber form, shielding the flame, and the flame moving to the opposite side. Specifically, the flame-retardant nonwoven fabric of the present invention is sandwiched between the surface fabric of upholstered furniture such as mattresses, chairs, sofas, etc. and urethane foam or stuffed cotton that is an internal structure. Therefore, in the event of a fire, flames can be prevented from igniting the internal structure, and damage can be minimized. Non-woven fabric production methods such as general thermal bond method, chemical bond method, water jet method, needle punch method, stitch bond method, etc. can be used as a method for producing a flame retardant nonwoven fabric. After blending, the card is opened and a web is created, and this web is applied to a non-woven fabric production device. In view of the simplicity of the apparatus-if a single-punch method or a polyester-based low-melting binder single fiber is used, it is not limited to these methods, which are generally manufactured by a thermal bond method.

[0047] When the upholstered furniture is produced using the flame retardant fiber composite of the present invention, the flame retardant fiber composite of the present invention has excellent characteristics, that is, excellent flame retardancy, texture, touch, moisture absorption. Upholstered furniture products with excellent properties such as stability and design.

Example

[0048] Hereinafter, the present invention will be described in more detail with reference to examples. However, the present invention is not limited to only the examples. The flame retardancy of the fibers in the examples was measured using a nonwoven fabric as described below. This is because the flame-retardant nonwoven fabric of the present invention is sandwiched between the surface fabric of upholstered furniture such as mattresses, chairs, sofas, etc. and the urethane foam or cotton pad that is the internal structure. This is a simple evaluation method based on the image of preventing the ignition of internal structures.

(Flame retardant evaluation 1, Flame retardant evaluation by non-woven fabric)

1) Preparation of non-woven fabric for flame retardant evaluation test

(Mixed at a predetermined ratio (in the case of fiber composite)) After weaving the fibers with a card, a non-woven fabric with a basis weight of 200 gZm ² and a fabric weight of 20 cm x 20 cm was created by the double dollar punch method 2) Flame retardant evaluation test method using non-woven fabric

Prepare a pearlite plate with a length of 200mm x width 200mm x thickness 10mm with a hole with a diameter of 15cm, and set a non-woven fabric for flame retardant evaluation test on it. The four sides were fixed with clips so that they did not shrink. With this sample facing the flame retardant evaluation nonwoven fabric surface, the center of the sample and the center of the burner are aligned with a gas stove (PA-10H-2) manufactured by Paloma Industry Co., Ltd., 40 mm from the burner surface. I set it. Propane with a purity of 99% or more was used as the fuel gas, the flame height was 25 mm, and the ignition time was 180 seconds. At this time, the evaluation was carried out with ◯ when there was no through hole in the carbonized film of the non-flammability evaluation test nonwoven fabric or when there was no crack, and X when there was a hole or crack.

(Flame resistance evaluation 2, LOI value)

Take 2g of cotton prepared according to the following manufacturing example, divide it into 8 equal parts, make 8 pieces of about 6cm, stand upright on the holder of the oxygen index measuring instrument, and the minimum necessary for this sample to keep burning 5cm The oxygen concentration was measured and used as the LOI value. The higher the LOI value, the higher the flame retardant property.

(Processability evaluation)

In the preparation of the non-woven fabric for flame retardancy evaluation, observe the state of the web after passing through the card, and those that are not particularly problematic in processing are ◎, those that have some web sag but do not affect workability ◯, where the web sagging was large and the workability was a problem, △, and when the web was broken and difficult to machine, X was rated.

(Measurement method of halogen content in fiber)

The resulting copolymer was subjected to elemental analysis on C element, H element, and N element by Yanako CHN coder MT-5 manufactured by Yanagimoto Mfg. Co., Ltd. The acrylonitrile component content in the coalescence was determined. Further, it was assumed that the total amount of p-styrene sulfonic acid soda was copolymerized, and the remainder was determined to be a component derived from a rogen monomer, and the halogen content in the halogen-containing copolymer obtained by calculation was determined.

(Production example) A copolymer of 51% acrylonitrile, 48% vinylidene chloride and 1% sodium p-styrene sulfonate was dissolved in dimethylformamide so that the concentration of the resin was 30%. Kaolin and antimony triacid antimony were added at the addition amounts shown in Table 1 with respect to the weight to prepare a spinning dope. The kaolin and antimony trioxide-antimony had a particle diameter of an average particle diameter of 2 m or less, and were used by adjusting in advance so as to be uniformly dispersed in a diluted resin solution.

[0049] A spinning stock solution containing kaolin and Z or antimony trioxide is extruded into a 50% aqueous dimethylformamide solution using a nozzle with a nozzle hole diameter of 0.10 mm and a hole number of 1000 holes, washed with water and then 120 ° After drying at C and then stretching 3 times, a heat treatment was further performed at 150 ° C for 5 minutes to obtain a halogen-containing fiber. The obtained fiber had a halogen content of 35.1% based on the weight of the halogen-containing copolymer. The obtained fiber was a short fiber having a fineness of 5.6 dtex and a cut length of 5 lmm.

(Examples 1 to 3, Comparative Examples 1 to 3)

According to the production example, a halogen-containing fiber was prepared by adding kaolin and antimony trioxide antimony in the amounts shown in Table 1, and the flame retardancy was evaluated. The results are shown in Table 1.

[0050] The combustion test results of Examples 1 to 3 were good, and the non-woven fabric for flame retardancy evaluation test formed a good carbonized film that did not generate cracks or holes even after heating with a gas outlet. On the other hand, in Comparative Examples 1 and 2, a good carbonized film could not be formed because there was little kaolin, and holes were formed in the nonwoven fabric.

[0051] In Comparative Example 3, the total amount of the flame retardant is the same as in Example 1, and the LOI value is almost the same as in Example 3. Since kaolin is not included, a good carbonized film cannot be formed. A hole was formed in the nonwoven fabric.

[0052] Table 1 below shows the flame retardancy evaluation test results of Examples 1 to 3 and Comparative Examples 1 to 3.

[0053] [Table 1] table 1

[0054] (Examples 4-7, Comparative Examples 4-8)

According to the production example, a halogen-containing fiber added with kaolin and antimony trioxide antimony in the amounts shown in Table 2 was prepared. The resulting halogen-containing fiber, polyester fiber (6.6 dtex, cut length 51 mm), rayon fiber ( (1) 5dtex, cut length 38mm) Nonwoven fabric was prepared at the specified ratio, and the flame retardancy was evaluated. The results are shown in Table 2.

[0055] The combustion test results of Examples 4 to 7 were good, and the non-woven fabric for flame retardancy evaluation test formed a good carbonized film that did not generate cracks or holes even after heating with a gas outlet. On the other hand, in Comparative Example 4, a good carbonized film could not be formed because there was little kaolin, and holes were formed in the nonwoven fabric.

[0056] In Comparative Examples 5 and 6, the total amount of the flame retardant was the same as in Example 4. Since kaolin was not included, a good carbonized film could not be formed, and holes were formed in the nonwoven fabric.

[0057] In Comparative Example 7, the amount of halogen-containing fibers was small compared to Examples 5 and 6, and a good carbonized film was not formed.

[0058] In Comparative Example 8, the ratio of the halogen-containing fiber is 100% and the kaolin content is sufficient, so that the flame retardancy is good, but because it does not contain natural fiber and Z or chemical fiber There was a problem with processability.

[0059] Table 2 below shows the flame retardancy evaluation test results of Examples 4 to 7 and Comparative Examples 4 to 8.

[0060] [Table 2] Table 2

[0061] (Example 8 12, Comparative Example 9 12)

In accordance with the production example, a halogen-containing fiber was prepared by adding kaolin and antimony trioxide and antimony in the amounts shown in Table 3. The resulting halogen-containing fiber, polyester fiber (6.6 dtex, cut length 51 mm), rayon fiber ( (1) 5dtex, cut length 38mm) Nonwoven fabric was prepared at the specified ratio, and the flame retardancy was evaluated. The results are shown in Table 3.

[0062] In Example 8-12, the result of the combustion test was good, and the non-woven fabric for flame retardancy evaluation test formed a good carbonized film that did not cause cracks or holes after heating with a gas outlet. On the other hand, in Comparative Example 9, a good carbonized film could not be formed because there was less kaolin, and holes were formed in the nonwoven fabric.

[0063] In Comparative Examples 10 and 11, the total amount of the flame retardant was the same as that in Example 8. However, since kaolin was not included, a good carbonized film could not be formed, and holes were formed in the nonwoven fabric.

[0064] In Comparative Example 12, the amount of halogen-containing fibers was small compared to Examples 10 and 11, and a good carbonized film was not formed.

[0065] Table 3 below shows the results of the flame retardancy evaluation test of Example 812 and Comparative Example 912.

[0066] [Table 3] Table 3

Industrial applicability

The flame-retardant synthetic fiber of the present invention, the flame-retardant composite comprising the same, and the upholstered furniture product using the texture, texture, or touch? It is possible to obtain a textile product having a high flame retardance that is excellent in design such as appearance and processability and can withstand a long flame.

Claims

The scope of the claims

[1] A flame-retardant synthetic fiber containing 5 to 50 parts by weight of kaolin with respect to 100 parts by weight of a polymer containing at least 17% by weight of rouge and rogen.

[2] Polymer power containing 17% by weight or more of the halogen 30 to 70 parts by weight of acrylonitrile, 70 to 30 parts by weight of halogen-containing buler monomer, and 0 to 10 parts by weight of a buler monomer copolymerizable therewith The flame-retardant synthetic fiber according to claim 1, further comprising:

[3] The flame-retardant synthetic fiber according to claim 1 or 2, wherein the halogen-containing power of the polymer containing halogen is 20 to 86% by weight of the polymer.

[4] The flame-retardant synthetic fiber according to any one of claims 1 to 3, wherein an average particle size of the kaolin is 2 m or less.

[5] The flame retardancy according to any one of claims 1 to 4, wherein the total amount of kaolin and other additives is 6 to 50 parts by weight with respect to 100 parts by weight of the polymer containing 17% by weight or more of the halogen. Synthetic fibers.

[6] The other additive is an Sb compound, hexabromobenzene, hexacyclodicyclohexane, a halogen compound such as chlorinated paraffin, a halogen-containing phosphorus compound, an ammonium polyphosphate, a phosphorus compound such as dibutylaminophosphate, 6. The flame retardant according to claim 5, wherein the compound is selected from a magnesium compound, a tin compound, a zinc compound, a molybdenum compound, a titanium compound, a melamine sulfate, an aluminum compound, a zirconium compound, and a glass power. Synthetic fibers.

[7] The flame retardant synthetic fiber according to claim 5, comprising 1 to 45 parts by weight of an Sb compound as the other additive.

[8] The Sb compound contains antimony oxide (Sb 2 O 3, Sb 2 O 3, Sb 2 O 3), antimonic acid and

2 3 2 4 2 5

A compound power selected from the salts and inorganic antimony compounds.

7. Flame-retardant synthetic fiber according to 7.

[9] Fiber containing 5 to 50 parts by weight of kaolin to 100 parts by weight of polymer containing 17% by weight or more of rosin and rogen (A) 40 parts by weight or more of natural fiber and Z or chemical fiber At least one type of fiber (B) Flame retardant fiber composites and upholstered furniture products using the flame retardant fiber composites of 60 parts by weight or less.

[10] Polymerization strength acrylonitrile 30-70 wt ^_0/0 containing the halogen, the halogen-containing bi - than Le monomer 70-30 wt% and copolymerizable with these vinyl monomer 0-10% by weight The flame-retardant fiber composite and the upholstered furniture product according to claim 9, wherein

[11] The flame retardant fiber composite and fabric tension according to claim 9 or 10, comprising 6 to 50 parts by weight of a total of kaolin and other additives with respect to 100 parts by weight of the polymer containing 17% by weight or more of the halogen. Furniture products.

[12] The flame retardant fiber composite and the upholstered furniture product according to any one of claims 9 to L1, wherein the average particle diameter of the kaolin is 2 m or less.

[13] The flame retardant fiber composite and the upholstered furniture product according to claim 12, comprising 1 to 45 parts by weight of an Sb compound as the other additive.

[14] The Sb compound contains antimony oxide (Sb 2 O, Sb 2 O, Sb 2 O 3), antimonic acid and

2 3 2 4 2 5

14. The flame-retardant fiber composite and the upholstered furniture product according to claim 13, characterized in that the compound power selected from salts and inorganic antimony compounds is also obtained.

[15] The flame retardant fiber according to any one of claims 9 to 14, comprising 40 parts by weight or less of a polyester fiber with respect to 100 parts by weight of at least one of the natural fiber and Z or chemical fiber (B). Complex and upholstered furniture products.

16. The flame retardant fiber composite and upholstered furniture product according to claim 15, wherein the polyester fiber as the fiber (B) is a low melting point binder fiber.

[17] A nonwoven fabric comprising the flame retardant fiber composite according to any one of claims 9 to 16, and a upholstered furniture product, wherein the flame retardant fiber composite is a nonwoven fabric.

18. The nonwoven fabric for flame shielding barrier according to claim 17, and the upholstered furniture product according to claim 17, wherein the nonwoven fabric is a nonwoven fabric for flame shielding barrier.