WO2006134931A1

WO2006134931A1 - Flame-retardant low-resilience urethane foam mattress

Info

Publication number: WO2006134931A1
Application number: PCT/JP2006/311854
Authority: WO
Inventors: Masanobu Tamura; Susumu Iwade; Wataru Mio; Shigeru Maruyama
Original assignee: Kaneka Corporation
Priority date: 2005-06-14
Filing date: 2006-06-13
Publication date: 2006-12-21
Also published as: JP2008206529A

Abstract

A flame-retardant low-resilience urethane foam mattress which is a mattress comprising a flame-barrier fabric and a low-resilience urethane foam covered therewith. The flame-barrier fabric is composed of fibers which comprise 0-70 wt.% halogenated fibers (A), 0-70 wt.% flame-retardant cellulosic fibers (B), 0-75 wt.% cellulosic fibers (C), and 0-30 wt.% polyester fibers (D), provided that [(A)+(B)+(C)+(D)]=100 wt.% and 25 wt.%≤[(A)+(B)]≤75 wt.%, preferably 30 wt.%≤[(B)+(C)]. The fabric covering the low-resilience urethane foam has a total thickness of 1.3 mm or larger. The mattress sufficiently shows the flexibility and comfortableness which are characteristic of the low-resilience urethane foam. The fabric covering the low-resilience urethane foam retains the intact excellent texture, touch feeling, etc. possessed by the fibrous material. The mattress is comfortable and has high flame retardancy.

Description

Specification

Flame retardant low resilience urethane foam mattress

Technical field

[0001] The present invention relates to a flame-retardant low-resilience urethane foam mattress in which a low-resilience urethane foam is covered with a flame-shielding fabric.

Background art

[0002] Low-resilience urethane foam is a foam with many open cells with a large specific gravity, and has a unique flexibility and comfort, so the internal structure of bedding products such as pillows and mattresses and interior textile products It is starting to be used as a thing. Ordinary urethane foam burns without producing a melt when exposed to specific gravity and flame. However, low-resilience urethane foam forms a melt when exposed to flames, which oozes out side forces, making it difficult to extinguish once combustion begins. Accordingly, the low-resilience urethane foam is required to have high flame resistance.

[0003] Also, in recent years, bedding products and interior textile products have been required to have a high degree of flame retardancy, such as being in contact with flames for a long time, for example, 70 seconds, The Such flame retardancy is described, for example, in Technical Bullet in 603 (hereinafter referred to as “TB603”) which is a mattress combustion test method in California, USA. However, it is not easy to obtain bedding products using low-resilience urethane foam that have high flame retardance that does not burn even when in contact with flame for a long time as specified in TB603. In addition, bedding products and interior textile products must have a touch that is not only flame retardant, a comfort such as moisture absorption, and an excellent appearance and texture.

[0004] Conventionally, various flame-retardant fibers and flameproofing agents for imparting flame retardancy to bedding products and interior products have been studied. However, mattresses using low-resilience urethane foam that combine the above-mentioned high flame retardancy with comfort, appearance and texture have yet to appear.

[0005] As a method for imparting flame retardancy to bedding products and interior textile products, for example, there is a so-called post-processing flameproofing method in which a flameproofing agent is applied to a woven fabric such as cotton cloth used in a side fabric. Shi However, this post-processing flameproofing includes variations in flameproofing performance due to non-uniform adhesion of flameproofing agents, a decrease in comfort such as tactile sensation due to fabric curing due to the adhesion of flameproofing agents, and prevention due to dropping off of the flameproofing agent. There were problems such as reduced flame performance.

[0006] In addition, fabrics using inorganic fibers such as glass fibers are excellent in flame retardancy! / Glasses, but because glass fibers are hard, glass fibers are used in the manufacturing process of yarns and fabrics. In addition to poor processability such as fiber opening, the resulting fabric has the disadvantages of low hygroscopicity, poor touch, and low dyeability.

[0007] Further, a fabric made of heat-resistant fibers is excellent in flame retardancy! In addition, the heat-resistant fiber is also hard, so that the processability such as card opening in the yarn and fabric manufacturing process is poor, and the resulting fabric has low hygroscopicity, poor touch, and low dyeability. There is a shortcoming.

[0008] As a material that can be used for bedding products and interior textile products, has an excellent texture, hygroscopicity, tactile sensation, and has a stable flame retardancy, a large amount of a flame retardant is added to a high degree. There have been proposed interior fiber products and bedding fiber products made of a flame retardant fiber composite that combines a flame retardant halogen-containing fiber with a flame retardant fiber and other fibers (for example, patents). See Document 1, Patent Document 2, etc.) ₀ However, these flame retardant fiber composites are not used for extremely flammable and low melting materials such as low resilience urethane foam.

[0009] In addition, a bulky flame-retardant nonwoven fabric (Patent Document 3) containing essentially flame-retardant fibers and halogen-containing fibers, and halogen-containing polyacrylonitrile fibers and supporting them during combustion (burned fibers) Proposal of flame retardant nonwoven fabric made of fiber (Patent Document 4), flame retardant nonwoven fabric made of flame retardant rayon fiber, flame retardant acrylic fiber and flame retardant melamine fiber (Patent Document 5) Has been. These are all techniques using a nonwoven fabric. However, non-woven fabrics lack the softness and elasticity of knit fabrics, so if non-woven fabric is used as a side of bedding products and interior textile products, cotton and low-resilience urethane foam used as internal structures will not be used. It was a flame retardant technology that was inferior in comfort because it lost the flexibility, comfort, and texture of the material.

Patent Document 1: Japanese Patent Laid-Open No. 05-106132

Patent Document 2: Japanese Patent Laid-Open No. 05-093330 Patent Document 3: Pamphlet of International Publication No. 03Z023108

Patent Document 4: US Patent Application Publication No. 2004Z0062912A1

Patent Document 5: US Patent Application Publication No. 2004Z0097156A1 Specification

Disclosure of the invention

Problems to be solved by the invention

[0011] An object of the present invention is to perform a test for contact with a flame for a long period of time as defined in TB603 while using a low-resilience urethane foam that is easy to burn while having unique flexibility and comfort. It is to provide a flame-retardant low-resilience urethane foam mattress that can prevent combustion even at low temperatures.

Means for solving the problem

[0012] As a result of intensive studies to solve the above problems, the present inventors have made the halogen-containing fiber (A) and Z or the flame-retardant cellulosic fiber (B) an essential component, and if necessary, Composed of a fiber containing cellulosic fibers (C) and polyester fibers (D) to form a flame-shielding fabric, which covers the low-resilience urethane foam as an internal structure, making it unique to low-resilience urethane foam A flame-retardant low-resilience urethane foam mattress that has excellent texture, moisture absorption, and touch without damaging performance and comfort and that can withstand long-term flames. I found.

[0013] That is, the flame-retardant low-resilience urethane foam mattress according to the present invention is obtained by coating a low-resilience urethane foam with a single layer or a plurality of layers of fabric, and at least one layer of the fabric containing halogen-containing fibers (A ) 0-75 wt%, flame retardant cellulosic fiber (B) 0-75 wt%, cellulosic fiber (C) 0-75 wt% and polyester fiber (D) 0-30 wt% [(A) + (B) + (C) + (D)] = 100 wt%, 25 wt% ≤ [(A) + (B)] ≤ 75 wt% flame-shielding fabric composed of fibers, said The total thickness of the fabric covering the low-resilience urethane foam is 1.3 mm or more.

[0014] Further, the mattress of the present invention is the above flame-retardant low-resilience urethane foam mattress in which the flame-shielding fabric is composed of fibers satisfying 30 wt% ≤ [(B) + (C)]. is there.

[0015] In addition, the mattress of the present invention, the flame shielding fabric, [(A) + (C ) + (D)] = 100 by weight ^_0/0 The flame retardant comprised of fibers that are Low resilience urethane foam mattress [0016] Further, the mattress of the present invention is the flame-retardant low-resilience urethane foam mattress in which the flame shielding fabric is composed of fibers having [(A) + (C)] = 100 wt%.

[0017] In addition, the mattress of the present invention, the flame shielding fabric, [(B) + (C ) + (D)] = 100 by weight ^_0/0 The retardant foam comprised of fibers that are It is a urethane foam mattress.

[0018] Further, the mattress of the present invention is the above flame-retardant low-resilience urethane foam mattress, wherein the flame-shielding fabric is composed of fibers with [(B) + (C)] = 100% by weight. .

[0019] Modacrylyl is preferred as the halogen-containing fiber (A) in the low-resilience urethane foam mattress of the present invention.

[0020] The flame-retardant cellulosic fiber (B) in the low-resilience urethane foam mattress of the present invention is at least selected from the group consisting of cotton, hemp, rayon, polynosic, cuvula, acetate and triacetate. the one fiber, it is rayon fibers 2 0-50 wt ^_0/0 contains at least one as a flame retardant that is a fiber which contains a flame retardant selected preferred instrument silicate, and aluminum silicate force Is more preferable.

[0021] Further, as the flame retardant cellulose fiber (B), phosphate ester compounds, halogen-containing phosphate ester compounds, condensed phosphate ester compounds, polyphosphate compounds, red phosphorus, amine compounds At least one flame retardant selected from the group consisting of products, boric acid, halogenated compounds, urea formaldehyde compounds, ammonium sulfate, and guanidine condensate. -25% by weight attached fiber is also preferred.

[0022] The cellulosic fiber (C) is a cotton fiber that is preferably at least one type of fiber selected from the group consisting of cotton, hemp, rayon, polynosic, cupra, acetate and triacetate. It is more preferable.

[0023] The polyester fibers (D) are preferably ordinary polyester fibers and Z or low-melting noinder fibers. The low melting point binder fiber is at least selected from the group consisting of a fiber composed of a single component of a low melting point polyester, a composite fiber of a normal polyester and a low melting point polyester, and a composite fiber of a normal polyester and a low melting point polyolefin. One type of fiber is more preferable.

[0024] In the flame-shielding fabric used in the flame-retardant low-resilience urethane foam mattress of the present invention Preferably contains 2-40% by weight of flame retardant.

[0025] Further, the flame-shielding fabric used for the flame-retardant low-resilience urethane foam mattress of the present invention preferably contains 2 to 20% by weight of an Sb compound.

[0026] Further, the flame-retardant low-resilience urethane foam mattress of the present invention covers the low-resilience urethane foam with a flame shielding fabric which is a knitted fabric, and further covers the outside with a side fabric made of a pile-shaped knitted fabric. Is preferred.

[0027] Furthermore, it is preferable that the flame-retardant low-resilience urethane foam mattress of the present invention is made of a flame-shielding cloth that has a pile-like knitted fabric. In this case, it is preferable to use cellulosic fibers (C) or polyester fibers (D) as the ground yarn of the pile fabric.

[0028] Further, the flame-retardant low-resilience urethane foam mattress of the present invention preferably has a total weight of 300 g / m ² or more of the fabric weight of a single layer or a plurality of layers covering the low-resilience urethane foam.

The invention's effect

[0029] The flame-retardant low-resilience urethane foam mattress of the present invention comprises 25% by weight ≤ [(A) + () containing halogen-containing fibers (A) and Z or flame-retardant cellulosic fibers (B) as essential components. B)] The total thickness of the fabric covering the low-resilience urethane foam with a flame-shielding fabric composed of fibers contained in the range of ≤75% by weight and covering the low-resilience urethane foam shall be 1.3 mm or more. The fabric that covers the low-resilience urethane foam does not impair the excellent texture and feel of the fiber material. Therefore, it is possible to provide a flame retardant low-resilience urethane foam mattress that is comfortable and has high flame retardancy.

[0030] Further, the flame-shielding fabric contains flame retardant cellulosic fibers (B) and Z or cellulose fibers (C) in the range of 30 wt% ≤ [(B) + (C)]. When composed of fibers, a flame-retardant, low-resilience urethane foam mattress with excellent moisture absorption, texture, and feel can be obtained.

BEST MODE FOR CARRYING OUT THE INVENTION

[0031] In the flame-retardant low-resilience urethane foam mattress of the present invention, the low-resilience urethane foam mattress as an internal structure is covered with a flame shielding fabric. [0032] The low-resilience urethane foam mattress referred to in the present invention includes a so-called bedding mattress as a thick mattress to be used under a mattress or a bed, and a bed sofa (futon), etc. Furthermore, if it has a structure in which a low-resilience urethane foam, which is not limited to these, is covered with a cloth, it covers all products such as bedding products, interior textile products, and upholstered furniture products.

[0033] The low-resilience urethane foam used in the present invention is a kind of flexible urethane foam, which is a urethane foam designed to have a special molecular structure and reduced in elasticity, and has a high hysteresis loss rate (JIS K 6400-2). ) With large shock-absorbing foam characteristics. This low-resilience urethane foam has the property of returning to its original shape when the external force is removed after the air bubbles are connected and compressed. The low-resilience urethane foam is produced by stirring and mixing a foaming agent, a foam stabilizer, a catalyst, etc. with a polyol and a polyisocyanate as main components in the same manner as a general urethane foam. Examples thereof include, but are not limited to, those having a pressure distribution function represented by Tempur World (registered trademark) material manufactured by Tempur World, Inc. Low resilience urethane foam has a rebound resilience of about 15% or less compared to general urethane foam, CF IS K 6400-3). For this reason, when low-resilience urethane foam is used for mattresses, pillows, bedding, chairs, etc., it has a high elasticity recovery rate and flexibility, and also has a low repulsive force. The pressure is applied to the body to disperse the pressure, and there is little local pressure, which is effective in preventing blood flow problems and bedsores. In addition, the low-resilience urethane foam has features such as being easy to care for due to its excellent moisture release properties.

[0034] On the other hand, low resilience urethane foam has low foaming ratio and high density compared to general urethane foam, so it easily burns with a large amount of gas generated per unit volume when combusted. Besides, the burning time is long. In addition, general urethane foam burns vividly without drip during combustion, but low-resilience urethane foam drips the molten resin in the combustion process, which makes it difficult to use as an internal structure of a mattress. It is more difficult to make it flammable.

[0035] The flame-retardant low-resilience urethane foam mattress of the present invention is a low-resilience urethane as described above. The flameproofing fabric that covers the foam provides flameproofness, has flame retardancy that can prevent the spread of fire to a low-resilience urethane foam, and has excellent strength that is inherent to fibers that make up the material of flameshielding fabric. The texture, feel, and hygroscopicity are not impaired and the comfort is maintained.

[0036] As the fabric covering the low-resilience urethane foam, only one flame-shielding fabric (single layer) may be used (single layer). In addition, two or more fabrics including at least one flame shielding fabric may be used in combination (multiple layers). That is, when two or more fabrics covering low-resilience urethane foam are used, as long as at least one flame-shielding fabric is included, the other fabrics are usually used as the side of the mattress! But! /

[0037] The flame-shielding fabric used in the present invention may be used as a side surface for forming the outer surface of the low-resilience urethane foam mattress, or may be sandwiched between the side surface and the low-resilience urethane foam. . In the present invention, the term “side” refers to the outermost fabric among the fabrics covering the outside of the low-resilience urethane foam, which is an internal structure of the mattress, and refers to the fabric covering the low-resilience urethane foam. When more than one sheet is used, it refers to the fabric that forms the surface layer of the low-resilience urethane foam mattress located on the outermost side. If there is only one fabric covering the low resilience urethane foam, the flame-shielding fabric will help the traditional side. Also, when using a flame-shielding fabric sandwiched between the side fabric and the low-resilience urethane foam, the side fabric is used as a conventional fabric and a flame-shielding fabric is used between the side fabric and the low-resilience urethane foam. It can be used by sandwiching it, or the side can be used as a flame-shielding fabric, and the surface of the low-resilience urethane foam can be covered with two flame-shielding fabrics. When using a flame-shielding fabric sandwiched between the side ground and the low-resilience urethane foam, it is a matter of course to cover the entire low-resilience urethane foam with the flame-shielding fabric and then cover it with the side ground from above. .

[0038] The flame-shielding fabric used in the present invention contains halogen-containing fibers (A) and Z or flame-retardant cellulosic fibers (B) as essential components, and if necessary, cellulosic fibers (C) and Consists of at least two types of fibers containing Z or polyester fibers (D).

[0039] Of the components (A) to (D), a flame shielding fabric is formed from at least two types of fibers. Examples of the method include, but are not limited to, blended cotton, blended spinning, and knit.

[0040] The term "flame shielding" as used herein means that when the fabric surface is exposed to flame, the fabric is carbonized while maintaining the fiber form, thereby shielding the flame and opposite to the surface exposed to the flame. It is to prevent the flame from moving to the surface. Specifically, by using at least one flame-shielding fabric as the fabric covering the low-resilience urethane foam, it prevents flame ignition to the low-resilience urethane foam that is an internal structure when exposed to flame, It can eat and stop burning to a minimum.

[0041] The flame shielding fabric is preferably a knitted fabric. By using a flame-shielding fabric as a knitted fabric, it has sufficient stretch allowance to expand and contract in the vertical and horizontal directions compared to fabric, and the thickness of the fabric is not as thin as a nonwoven fabric. It is possible to fully demonstrate the flexibility and comfort unique to urethane foam materials. In general, the fibers show shrinkage when forming a carbonized film during combustion, and the carbonized film that has lost its rigidity is prone to cracking. Since it has a sufficient elongation allowance for expansion and contraction, a very good carbonized film without cracks is formed. There are no particular restrictions on the method of knitting the flame-shielding knitted fabric, either weft knitting or warp knitting. The shape of the knitted fabric is not particularly limited, but when using a flame-shielding fabric as a side fabric, it is preferable to use a pile-shaped knitted fabric with a raised surface because the tactile feeling is particularly excellent. Furthermore, it is preferable to use cellulosic fibers (C) or polyester fibers (D) as the ground yarn of the pile fabric.

[0042] The flame-shielding fabric used in 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. .

[0043] The flame-shielding fabric as described above has high flame-shielding properties, is excellent in texture, touch, moisture absorption, etc., and has good dyeability and high design properties.

[0044] The low-resilience urethane foam mattress of the present invention covered with the flame-shielding fabric as described above sufficiently exhibits the unique flexibility and comfort of the low-resilience urethane foam, while shielding the flame. Due to the excellent characteristics of the fabric, it has high flame retardancy, is excellent in texture, touch, moisture absorption, etc., is comfortable, has a strong dying property and a high design.

[0045] The halogen-containing fiber (A) used in the present invention is a component used for improving the flame retardancy of the flame-shielding fabric, and generates an oxygen-deficient gas during combustion, thereby producing a flame-shielding fabric surface. It has the effect of promoting self-extinguishing of flames on the surface. Examples of the halogen-containing fiber (A) include homopolymers and copolymers of halogen-containing monomers such as vinyl chloride and vinylidene chloride, monomers copolymerizable with these halogen-containing monomers, such as acrylonitrile, styrene, and acetic acid. Examples of such fibers include, but are not limited to, copolymers such as vinyl and acrylate esters, or graft polymers in which a halogen-containing monomer is grafted onto a PVA polymer. Among these halogen-containing fibers (A), modacrylyl is a fiber that also has a copolymer power of a halogen-containing monomer and acrylonitrile in terms of providing flame-retardant fabrics with flame retardancy and excellent texture, touch and design. Is preferably used.

It is preferable that a flame retardant is added to the halogen-containing fiber (A) in order to enhance the flame retardancy of the flame shielding fabric. Specific examples of flame retardants include Sb compounds such as antimony trioxide, antimony pentoxide, antimonic acid, and antimony oxychloride, stannic oxide, metastannic acid, stannous oxyhalide, stannic oxyhalide, and hydroxide Sn compounds such as stannous chloride and tin tetrachloride, Zn compounds such as acid zinc, Mg compounds such as magnesium oxide, magnesium hydroxide, Mo compounds such as molybdenum oxide, oxidation Ti compounds such as titanium and barium titanate, N compounds such as melamine sulfate and guanidine sulfamate, P compounds such as ammonium polyphosphate, dibutylaminophosphate, aluminum hydroxide, sulfuric acid A1 compounds such as aluminum and aluminum silicate, Zr compounds such as zirconium oxide, Si compounds such as silicate and glass, Olin, Zeoraito, montmorillonite, Tanoreku, pearlite, bentonite, Bamikiyura site, natural or synthetic mineral-based compounds such as diatomaceous earth, paraffin chloride, to Kisaburomo benzene, halogenated compounds such as Kisabu port mode cyclododecane like to. Also, composite compounds such as magnesium stannate, zinc stannate and zirconium stannate may be used. These flame retardants may be used alone or in combination of two or more. Among these, Sb-based compound power It reacts with halogen atoms released from halogen-containing fibers (A) such as modacrylic fiber during combustion to produce halogen-antimony and exhibits extremely high flame retardancy. This is preferable. Sb-based compounds added to halogen-containing fibers (A) such as modacrylic fibers are used to maintain the flame-retardant properties of flame-shielding fabrics. Add 2% by weight or more with respect to the entire ground, and add 20% by weight or less with respect to the entire flame-shielding fabric from the viewpoint of maintaining the texture and strength of the flame-shielding fabric. I prefer that. Specific examples of the modacrylic fiber as the halogen-containing fiber (A) include Kanekaron (registered trademark) of Kanechi Co., Ltd. and SEF (SEF) of Solutia Co., but are not limited thereto. Absent.

[0047] The flame-retardant cellulosic fiber (B) used in the present invention is used for improving the flame retardancy and maintaining the strength of the flame-shielding fabric, and is excellent in texture and moisture absorption and imparts comfort. In addition, it is a component that is effective in forming a carbonized film during combustion.

[0048] As the flame-retardant cellulose fiber (B), a silicic acid-containing cellulosic fiber containing silicic acid and Z or aluminum silicate as a flame retardant and other flame retardants were added to the cellulose fiber during production. Flame retardant cellulosic fibers and flame retardant cellulosic fibers that are flame retardant by post-processing using a flame retardant are used. Flame retardant cellulosic fiber (

Specific examples of cellulosic fibers that are substrates for B) include cotton, hemp, rayon, polynosic, cuvula, acetate, and triacetate. These may be used alone or in combination. May be.

[0049] The silicic acid-containing cellulosic fiber contains silicic acid and Z or aluminum silicate as a flame retardant in a fiber in an amount of 20 to 50 wt%, and usually has a fineness of about 1.7 to 8 dtex, It has a cut length of about 38-128mm. Specific examples thereof include, for example, Sateri Visil (registered trademark) containing about 30% by weight of silicic acid in the fiber, and Sateri containing about 30% by weight of aluminum silicate in the fiber. ) Company Visil AP. In addition, other flame-retardant cellulosic fibers include, but are not limited to, the power of Lenzing A. G. Lenzing FR.

[0050] Examples of the flame retardant used when the cellulose-based fiber is flame retardant by post-processing or the like include triphenyl phosphate, tricresyl phosphate, trixylenyl phosphate, trimethinorephosphate, and tritinorephosphate. Aromatic phosphates such as, credinolephenol phosphate, xylenyl diphosphate phosphate, resorcinol bis (diphenyl phosphate), 2-ethenorehexyl diphosphate phosphate; dimethyl phosphate, Phosphoric ester compounds such as triallyl phosphate (leophos), phosphonocarboxylic acid amide derivatives, tetrakis'hydroxymethylphosphonium derivatives, N-methyloldimethylphosphonopropionamide; tris (chloroethyl) phosphate, tris diclonal propyl Phosphate, tris-β-black propinorephosphate, chloroanolenoquinophosphate, tris (tribromoneopentinole) phosphate, jetinore ジェ, Ν-bis (2-hydroxyethyl) aminomethyl phosphate, tris (2 , 6 Dimethylphenol) Halogen-containing phosphate compounds such as phosphate; Aromatic condensed phosphate esters, halogen-containing condensed phosphate esters and other condensed phosphate ester compounds; Polyphosphate ammonia amide, Polyphosphate Oral polyphosphoric acid compounds such as phosphonates; polyphosphoric acid ester compounds such as polyphosphoric acid rubamate; red phosphorus; amine compounds; boric acid; halogen compounds such as bromides; urea urea formaldehyde compounds; ammonium sulfate; Examples thereof include guanidine-based condensates, and these may be used alone or in combination of two or more. The adhesion amount of the flame retardant is preferably 6 to 25% by weight based on the cellulosic fiber. In addition, in order to maintain the flame retardancy of the flame shielding fabric, it is attached so as to be 2% by weight or more with respect to the entire flame shielding fabric, and from the viewpoint of not impairing the texture of the flame shielding fabric. Adhere to less than 20% by weight with respect to the entire flame-shielding fabric.

[0051] The cellulosic fiber (C) used in the present invention is important for maintaining the strength of the flame-shielding fabric, is excellent in texture and hygroscopicity, provides comfort, and produces carbon during combustion. It is a component effective for forming a chemical film. Specific examples of the cellulosic fiber (C) include cotton, hemp, rayon, polynosic, cupra, acetate and triacetate, and these may be used alone or in combination of two or more. Among these, cotton, hemp, and rayon are preferable from the viewpoint of touch and hygroscopicity.

[0052] The polyester fiber (D) used in the present invention is a component for imparting excellent texture, touch, design, product strength, washing resistance and durability to a flame shielding fabric. Polyester fiber (D) itself is a flammable fiber, but melts during combustion, and the melt covers the carbonized film, thereby improving the strength of the resulting carbonized film. As the polyester fiber (D), it is also possible to use a polyester-based low melting point binder fiber. As polyester-based low-melting-point binder fiber, low-melting-point polyester single component It may be a parallel type or core-sheath type composite fiber made of a normal polyester, which is a low-melting point polyester, a low-melting point polypropylene, a low-melting point polyethylene, or the like. Generally, low melting point polyester has a melting point of approximately 110 to 200 ° C, low melting point polypropylene has a melting point of approximately 140 to 160 ° C, and low melting point polyethylene has a melting point of approximately 95 to 130 ° C. There is no particular limitation as long as it has melting adhesion ability at about 200 ° C. Examples of the low-melting point noder fiber include, but are not limited to, Safmet (SAFMET (registered trademark), 4.4 dtex X 51 mm, melting temperature 110 ° C.) manufactured by Toray Industries, Inc.

[0053] The fabric weight covering the low-resilience urethane foam is larger and is preferably 300 gZm ² or more from the viewpoint of flame shielding properties. When two or more fabrics, including at least one flame-shielding fabric, are used as the fabric covering the low-resilience urethane foam, the total weight of the fabric weight of two or more fabrics is 300 g / m ² or more. It is preferable. By setting the total fabric weight covering the low-resilience urethane foam to 300 gZm ² or more, the strength of the carbonized film formed at the time of combustion becomes sufficient and cracks are less likely to occur, and stable flame shielding performance can be exhibited.

[0054] The flame shielding fabric used in the present invention preferably has a flame retardant ratio of 2.0 to 40 wt% in the entire fabric. When the ratio of the flame retardant in the entire fabric is 2.0% by weight or more, it has excellent self-extinguishing ability during combustion and excellent ability to prevent ignition of low-rebound urethane foam as an internal structure.

[0055] In the present invention, as described above, as the fabric covering the low-resilience urethane foam, only one flame shielding fabric may be used, or at least two fabrics including at least one flame shielding fabric. However, in order to provide sufficient flame shielding performance and prevent the low-resilience urethane foam that has been decomposed and melted by the heat during combustion from leaching to the outside, low-resilience urethane foam may be used. The total thickness of the covering fabric must be at least 1.3 mm.

[0056] The flame-shielding fabric used in the present invention comprises halogen-containing fibers (A) 0 to 75% by weight, flame retardant cellulosic fibers (B) 0 to 75% by weight, cellulosic fibers (C) 0 to 75%. % By weight and polyester fiber (D) 0-30% by weight, [(A) + (B) + (C) + (D)] = 100% by weight And is composed of fibers that are 25% by weight ≤ [(A) + (B)] ≤ 75% by weight, and has excellent self-extinguishing properties, carbon film forming ability, texture, moisture absorption In addition, it is excellent in washing resistance and durability. Furthermore, by using fibers with 30 wt% ≤ [(B) + (C)], the texture and hygroscopicity are superior.

[0057] The proportion of the halogen-containing fiber (A) in the flame-shielding fabric needs to be 0 to 75% by weight. The halogen-containing fiber (A) is a component having high self-extinguishing properties. In particular, the halogen-containing fiber (A) containing an antimony compound does not have self-extinguishing properties! / When mixed with fibers, it works on fibers that do not have self-extinguishing properties and ignites the fabric. Has the property of extinguishing fire quickly. On the other hand, the carbon-containing film forming ability of the halogen-containing fiber (A) itself is weak and the strength of the formed carbon film is not so strong. If the proportion of the halogen-containing fiber (A) in the flame-shielding fabric exceeds 75% by weight, the proportion of the carbon film-forming component described below inevitably decreases, and the flame shielding performance is not satisfactory.

[0058] The ratio of the flame-retardant cellulosic fiber (B) in the flame-shielding fabric needs to be 0 to 75% by weight. The flame retardant cellulosic fiber (B) is a component having self-extinguishing properties and a carbonized film forming ability. The flame-retardant cellulosic fiber (B) works better against fibers that do not have self-extinguishing properties when mixed with fibers that do not have self-extinguishing properties, compared to halogen-containing fibers (A). Although it is weak, since it contains a flame retardant, it exhibits self-extinguishing properties. In addition, since the substrate of flame retardant cellulosic fiber (B) is a cellulosic fiber, it has a strong ability to form a carbonized film, and the shrinkage behavior when exposed to flame is moderate by rapid carbonization. It is possible to form a stable carbonized film. The flame-retardant cellulosic fiber (B) has a lower tactile sensation than the cellulosic fiber (C) that is not flame-retardant, so the proportion of flame-retardant cellulosic fiber (B) in the flame-shielding fabric If it exceeds 75% by weight, the feel of the low-resilience urethane foam mattress is lowered, and at the same time, workability such as opening with a card in the production process of yarn or fabric is deteriorated.

[0059] The proportion of the cellulosic fibers (C) in the flame-shielding fabric needs to be 0 to 75% by weight. Giving cellulosic fibers (C) gives excellent texture and hygroscopicity. In addition, since the cellulosic fiber (C) can be a carbonized component, it has the effect of improving the flame shielding performance of the flame shielding fabric. However, since the cellulosic fiber (C) is a combustible component, if the proportion of cellulosic fiber (C) exceeds 75% by weight, the combustible component in the flame-shielding fabric increases and sufficient flame-shielding performance cannot be obtained. Therefore, it is not preferable.

[0060] The proportion of the polyester fiber (D) in the flame shielding fabric needs to be 0 to 30% by weight. Addition of polyester fiber (D) can be expected to improve washing resistance and durability. In addition, it has the effect of improving the strength of the carbonized film by covering the flame-shielding fabric that has been carbonized by melting during combustion. . Since the polyester fiber (D) is flammable, if its proportion exceeds 30% by weight, the proportion of the burning component in the flame shielding fabric increases, and the flame shielding property is inferior.

[0061] Sum of halogen-containing fiber (A) and flame-retardant cellulosic fiber (B) in flame-shielding fabric

That is, the halogen-containing fiber (A) + the flame-retardant cellulosic fiber (B)) needs to be 25 to 75% by weight. Halogen-containing fiber (A) + flame-retardant cellulosic fiber (B) If the strength is less than% by weight, the self-extinguishing performance and carbonization ability of the flame-shielding fabric will be insufficient, and the flame-shielding performance will be insufficient. On the other hand, if the halogen-containing fiber (A) + flame-retardant cellulose fiber (B) exceeds 75% by weight, processability such as fiber opening by card in the manufacturing process of yarn and fabric becomes worse. This is not preferable because the tactile feeling is reduced.

[0062] The total of the flame-retardant cellulosic fiber (B) and the cellulosic fiber (C) in the flame-shielding fabric (that is, flame-retardant cellulosic fiber (B) + cellulosic fiber (C)) Is preferably 30% by weight or more. By making the flame-retardant cellulosic fiber (B) + cellulosic fiber (C) 30% by weight or more, excellent texture and moisture absorption of the cellulosic fiber can be obtained, and comfort is improved.

[0063] The flame-shielding fabric comprising the halogen-containing fiber (A), the flame-retardant cellulosic fiber (B), the cellulose fiber (C), and the polyester fiber (D) in the proportions as described above, It does not impair the excellent texture and feel, as well as the hygroscopicity and durability of the fiber material, and has a high level of flame retardancy. Therefore, by covering the low-resilience urethane foam with this flame-shielding fabric, it exhibits the flexibility and comfort unique to the material of the low-resilience urethane foam, and it is comfortable and has a high flame resistance. Flame retardant low resilience urethane foam mat Less is obtained.

[0064] Hereinafter, the present invention will be described in more detail with reference to examples. However, the present invention is not limited to these examples.

[0065] (Making method of flame retardant mattress)

The flame retardancy of the mattress was evaluated with a simple mattress prepared as follows. A low-resilience urethane foam is used as the internal structure, and a pile-shaped knitted fabric described later, a knitted fabric described later, or two pile-shaped knitted fabrics and a knitted fabric are overlapped as a fabric covering the low-resilience urethane foam. A simple mattress was created by completely covering the low-resilience urethane foam using a cloth and closing the mouth completely using force tan yarn. When using two piled knitted fabrics and knitted fabrics as the fabric covering the low-resilience urethane foam, completely cover the low-resilience urethane foam with the knitted fabric, and then use the pile-knitted fabric. Further covered completely. The low-resilience urethane foam was prepared by cutting a low-resilience urethane mattress manufactured by Tenpur World, Inc. into a length of 30 cm x width 45 cm x thickness 7.5 cm.

[0066] (Flame retardance evaluation method)

The flame retardancy evaluation of the mattress was performed according to Technical Bulletin 603 (TB603), a bed combustion test method in California, USA, using a simple mattress prepared according to the method for preparing a mattress for flame retardancy evaluation.

[0067] To briefly explain the TB603 combustion test method, a T-shaped burner was set vertically at a place where the side force of the bed (sample) was 42 mm away, and a horizontal T was placed 39 mm away from the top surface of the bed. Set a letter-shaped burner, propane gas is used as combustion gas, gas pressure is 10 IKPa, gas flow rate is 12.9 LZ for the upper surface, 6.6 LZ for the side, and the flame time is the upper surface 70 seconds, 50 seconds on the side, and total observation time is 30 minutes. If the maximum heat release is less than 200 Kw and the cumulative heat release for the first 10 minutes is less than 25 MJ, it is acceptable.

[0068] In this example, a simple mattress (sample) was flared under the same combustion test conditions as the TB603, and the flame retardance level was evaluated by the method of igniting the internal urethane foam. If the time required for the after flame or dust to disappear is 10 seconds or less, Among those that did not ignite the urethane foam, “○” indicates that the after flame and the time required for the residual dust to disappear have exceeded 10 seconds, and “X” indicates that the urethane foam flared. Was judged. In Tables 4 to 9, “forced fire extinguishing” indicates that the fire extinguished with water because it fired on the urethane foam. In addition, the state of the carbonized film after combustion is visually observed. The carbonized film is thick, strong, and has no holes. “Thick carbonized film” was evaluated as having a thin carbonized film with no holes. Furthermore, a case where the flame retardancy level was judged as “「 ”or“ ◯ ”and the state of the carbonized film after the powerful combustion was“ good ”was judged as“ pass ”as a comprehensive judgment.

[0069] (Production Example 1 of Halogen-Containing Fiber (A))

A copolymer obtained by copolymerizing 52 parts by weight of acrylonitrile, 46.8 parts by weight of sodium vinylidene, and 1.2 parts by weight of sodium styrenesulfonate was dissolved in acetone to obtain a 30% by weight solution. . A spinning stock solution was prepared by adding 8 parts by weight of antimony trioxide to 100 parts by weight of the copolymer. The obtained spinning dope was extruded into a 38 wt% acetone aqueous solution at 25 ° C. using a nozzle having a pore size of 0.07 mm and a hole number of 33,000, washed with water, and dried at 120 ° C. for 8 minutes. Thereafter, the film was stretched 3 times at 150 ° C. and heat-treated at 175 ° C. for 30 seconds to obtain a halogen-containing fiber (A) having a fineness of 2 dtex. The obtained halogen-containing fiber was oiled with a finishing oil for spinning (manufactured by Takemoto Yushi Co., Ltd.), crimped, and cut to a length of 51 mm.

[0070] (Production example 1 of flame retardant rayon fiber (B))

Rayon (Omikenshi Co., Ltd., Hope (registered trademark), fineness 1.5dtex, cut length 38mm) Ammonium polyphosphate (FCP-730, manufactured by Suzuhiro Chemical Co., Ltd.) is used as a flame retardant. 20% by weight with respect to the fiber.

[0071] (Production Examples 1 to 5 of spun yarn)

Production of Halogen-Containing Fiber (A) Halogen-containing fiber (A) prepared in Production Example 1 Silicate-containing rayon fiber (B) Visil (Visil (registered trademark), fineness 1.7. ex, cut length 40mm), flame retardant rayon fiber (B), cotton fiber (C), polyester fiber (D) prepared in Production Example 1 of flame retardant rayon fiber (manufactured by Toray Industries, Inc. Trademark), fineness 1.7dtex, cut length 51mm I got a yarn. The produced spun yarns of Production Examples 1 to 5 are shown in Table 1.

[0072] [Table 1] Table 1 Examples of spun yarn production

Note 1) Visil (registered trademark), manufactured by Sateri

Note 2) Tetoron (registered trademark) manufactured by Toray Industries, Inc.

[0073] (Pile-like knitted fabric production examples 1 to 35)

Spinning Yarn Production Examples 1 to 5 were used to knit a pile-shaped knit fabric using a well-known sinker pile knitting machine, and then the pile loop was cut by shearing as a finish. A pile-like knitted fabric with a basis weight shown in Fig. 1 was prepared.

[0074] [Table 2]

Table 2 Pile-like knitted fabric production examples

[0075] (Knit Fabric Production Examples 1-34)

Using the spun yarns prepared in Examples 1 to 5 of the spun yarn, knit fabrics with the blending ratio and basis weight shown in Table 3 were prepared using a well-known circular knitting machine.

[0076] [Table 3] Table 3 Production examples of knitted fabrics

[0077] (Examples 1 to 5)

Manufacturing Example of Knitted Knitted Fabric Using the pile-shaped knitted fabric created in 1-5, a mattress for evaluating flame retardancy was prepared according to the method for creating a mattress for evaluating flame retardancy, and the flame retardancy was evaluated.

[0078] (Comparative Examples 1 to 5)

Example of manufacture of knit fabric made of kneaded fabric Using the pile-shaped knitted fabric created in 19-23, a mattress for evaluating flame retardancy was prepared according to the method for creating a mattress for evaluating flame retardancy. Evaluation was performed.

[0079] The results of Examples 1 to 5 and Comparative Examples 1 to 5 are shown in Table 4, [0080] [Table 4]

Table 4 (Flame shielding fabric that is a pile-like knitted fabric)

[0081] As shown in Table 4, in Examples 1 to 5, the flame retardancy in the combustion test was good, and the overall judgment was acceptable. On the other hand, in Comparative Examples 1 and 2, since the self-extinguishing ability of the entire fabric with a small amount of halogen-containing fiber (A) + flame-retardant cellulosic fiber (B) was insufficient, a carbonized film was not formed. Weak holes were pierced and the low-resilience urethane foam ignited. Further, in Comparative Example 3, since there were many polyester fibers (D), it was difficult to form a carbonized film, and a hole was formed, and the low-resilience urethane foam was ignited. Furthermore, Comparative Examples 4 and 5 have self-extinguishing ability due to the large number of halogen-containing fibers, but cellulose-based fibers (C), which are carbonized film-forming components, and polyester-based fibers that have an effect of improving the strength of carbonized films (D ) Is insufficient, the comprehensive judgment that the carbonized film is quite thin was rejected. In addition, in Comparative Examples 4 and 5, the amount of flame retardant cellulosic fiber (B) + cellulosic fiber (C) is small! Therefore, properties such as hygroscopicity and elasticity and fabric texture are poor. !

[0082] (Example 6 to: L 1)

Example of Knitted Knitted Fabric Production Using the pile-shaped knitted fabric prepared in 6-11, a mattress for flame retardancy evaluation was created according to the method for creating a mattress for flame retardancy, and the flame retardancy evaluation was conducted. .

[0083] (Comparative Example 6-: LO)

Production Example of Knitted Knitted Fabric Using the pile-shaped knitted fabric prepared in 24-28, a mattress for evaluating flame retardancy was prepared according to the method for creating a mattress for evaluating flame retardancy, and the flame retardancy was evaluated.

[0084] Examples 6 to: The results of L 1 and Comparative Examples 6 to 10 are shown in Table 5.

[0085] [Table 5]

Table 5 (Flame-shielding cattle land that is a pile-like knitted fabric)

[0086] As shown in Table 5, in Examples 6 to 11, the flame retardancy in the combustion test was good, and the overall judgment was acceptable. On the other hand, in Comparative Examples 6 and 7, the amount of the flame retardant component fiber of the halogen-containing fiber (A) + the flame retardant cellulosic fiber (B) is small, and there are many non-flame retardant fibers! As a result, the flame shielding performance was poor and a hole was formed in the carbonized film, igniting the low-resilience urethane foam. Further, in Comparative Example 8, since there were many polyester fibers (D), it was difficult to form a carbonized film, and a hole was formed, and the low-resilience urethane foam was ignited. Furthermore, Comparative Examples 9 and 10 have a self-extinguishing ability because there are many flame retardant cellulose fibers (B), but the cellulose fibers (C), which are carbon film forming components, and carbon film strength are improved. The lack of effective polyester fiber (D) resulted in a failure in the comprehensive judgment that the carbonized film was weak and thin. In addition, in Comparative Examples 9 and 10, the properties such as hygroscopicity and elasticity and the texture of the fabric were poor.

[0087] (Examples 12 to 18)

Example of Knitted Knitted Fabric Production Using the pile-shaped knitted fabric created in 12-18, follow the method for creating a mattress for flame retardancy evaluation!マット A mattress for flame retardant evaluation was created and flame retardant evaluation was conducted.

[0088] (Comparative Examples 11 to 16)

Example of manufacturing knit fabric in the form of a knife Using the pile-shaped knit fabric created in 29-34, follow the method for creating a mattress for flame retardancy evaluation!マット A mattress for flame retardant evaluation was created and flame retardant evaluation was conducted.

The results of Examples 12 to 18 and Comparative Examples 11 to 16 are shown in Table 6.

[0090] [Table 6]

Table 6 (Flame shielding fabric that is a pile-like knitted fabric)

[0091] As shown in Table 6, in Examples 12 to 18, the flame retardancy in the combustion test was good, and the overall judgment was acceptable. However, in Example 18, the amount of cellulosic fibers of flame retardant cellulosic fibers (B) + cellulose fiber (C) is slightly smaller, so the hygroscopicity and elasticity are slightly inferior compared to other examples. It was. On the other hand, in Comparative Examples 11 and 12, the flame-shielding performance is low because the amount of the flame-retardant fiber of the halogen-containing fiber (A) + flame-retardant cellulosic fiber (B) is small and there are many non-flame-retardant fibers Inferior, a hole was made in the carbonized film, and the low-resilience urethane foam ignited. Further, in Comparative Examples 13 and 14, since there are many halogen-containing fibers (A) + flame-retardant cellulose fibers (B), there is a strong fire extinguishing ability. It was rejected in the overall judgment that was quite thin. In Comparative Examples 13 and 14, the hygroscopicity and the texture of the fabric were poor. Further, in Comparative Examples 15 and 16, since there were many polyester fibers (D), it was difficult to form a carbonized film and a hole was formed, and the low-resilience urethane foam was ignited.

[0092] (Examples 19 to 23)

Manufacture example of Knitted fabric Knit fabric manufactured in 35 and the knitted fabric manufactured in Examples 1 to 5 according to the method of creating a mattress for evaluating flame retardancy Mattress for evaluating flame retardancy The flame retardant evaluation was carried out.

[0093] (Comparative Examples 17 to 21)

Production Examples of Knitted Fabrics Using the knitted fabrics prepared in 1-5, a mattress for evaluating flame retardancy was prepared and evaluated for flame retardancy.

[0094] (Comparative Examples 22 to 26)

Example of manufacturing knit fabrics in the form of a knit fabric Manufacturing method of a mattress for flame resistance evaluation using the pile-shaped knit fabrics prepared in 35 and the knit fabrics prepared in Examples 19 to 23 A mattress was made and flame retardant evaluation was performed.

Table 7 shows the results of Examples 19 to 23, Comparative Examples 17 to 21 and Comparative Examples 22 to 26.

[0096] [Table 7] Table 7 (Flame shielding fabric that is knitted fabric)

[0097] As shown in Table 7, in Examples 19 to 23, the flame retardancy in the combustion test was good, and the overall judgment was acceptable. However, Example 36 was slightly inferior in hygroscopicity and elastic force because the amount of the flame-retardant cellulose fiber (B) + cellulosic fiber (C) in the knit fabric was slightly small. In contrast, in Comparative Examples 17-21, the thickness of the fabric covering the low-resilience urethane foam was insufficient, so a hole was formed in the carbonized film, and the low-resilience urethane foam ignited. Further, in Comparative Examples 22 and 23, the amount of halogen-containing fiber (A) + flame-retardant cellulosic fiber (B) is small, so the self-extinguishing performance is inferior, and a hole is formed in the carbonized film. Ignited. Furthermore, in Comparative Example 24, since there were many polyester fibers (D), it was difficult to form a carbonized film, and a hole was formed, and the low-resilience urethane foam was ignited. Furthermore, in Comparative Examples 25 and 26, since there are many halogen-containing fibers (A) + flame-retardant cellulose fibers (B), self-extinguishing ability is provided, but flame-retardant cellulose fibers (B) + cellulose fibers ( Due to the insufficient amount of C), the comprehensive judgment that the carbonized film is considerably thin was rejected. In Comparative Examples 25 and 26, the hygroscopicity and the texture of the fabric were poor.

[Examples 24-29]

Manufacture of Knitted Fabric Knit Fabric Pile Knit Fabric Created in 35 and Fabrication of Knit Fabric Example Using the knitted fabric prepared in Examples 6-11, follow the method for creating a mattress for flame retardancy evaluation! A mattress was made and flame retardant evaluation was performed.

[0099] (Comparative Examples 27 to 32)

Production Examples of Knitted Fabrics Using the knitted fabrics prepared in 6-11, a mattress for evaluating flame retardancy was prepared according to the method for creating a mattress for evaluating flame retardancy, and the flame retardancy was evaluated.

[0100] (Comparative Examples 33 to 37)

Manufacture of Knitted Fabric Knit Fabric Pile-shaped Knit Fabric Made in 35 and Fabricated Knit Fabric Example Follow the method of creating a mattress for flame retardant evaluation using the knitted fabric created in 24-28 ヽ Mattress for flame retardant evaluation The flame retardant evaluation was carried out.

[0101] Table 8 shows the results of Examples 24-29, Comparative Examples 27-32 and Comparative Examples 33-37.

[0102] [Table 8] Table 8 (Flame shielding fabric that is knitted fabric)

[0103] As shown in Table 8, in Examples 24-29, the flame retardancy in the combustion test was good, and the overall judgment was acceptable. On the other hand, in Comparative Examples 27 to 32, since the thickness of the cloth covering the low-resilience urethane foam was insufficient, a hole was formed in the carbonized film, and the low-resilience urethane foam was ignited. Further, in Comparative Examples 33 and 34, since the amount of halogen-containing fiber (A) + flame-retardant cellulosic fiber (B) is small, the self-extinguishing performance is inferior and a hole is formed in the carbonized film, resulting in a low resilience urethane foam. Ignited. Further, in Comparative Example 35, since there were many polyester fibers (D), it was difficult to form a carbonized film and a hole was formed, and the low repulsion urethane foam was ignited. Further, in Comparative Examples 36 and 37, there are many halogen-containing fibers (A) + flame retardant cellulosic fibers (B), so there is a fire extinguishing ability. Flame retardant cellulosic fibers (B) + cellulosic fibers (C) Due to the lack of quantity, the overall judgment that the carbonized film is quite thin was rejected. In Comparative Examples 36 and 37, the hygroscopicity and the texture of the fabric were poor.

[Examples 30 to 36]

Manufacture of Knitted Fabric Knit Fabric Pile-shaped Fabric Fabricated in 35 and Fabrication of Fabric Knit Fabric Example Using the knitted fabric fabricated in 12-18, according to the method of creating a mattress for flame retardancy evaluation A mattress was made and flame retardant evaluation was performed.

[0105] (Comparative Examples 38 to 44)

Production Examples of Knitted Fabrics Using the knitted fabrics prepared in Examples 12 to 18, a mattress for evaluating flame retardancy was prepared according to the method for creating a mattress for evaluating flame retardancy, and the flame retardancy was evaluated.

[0106] (Comparative Examples 45 to 50)

Manufacture example of knit fabric in pile shape Production of pile knitted fabric and knitted fabric prepared in Example 35 Using the knitted fabric prepared in Examples 29-34, follow the method for creating a mattress for flame retardant evaluation. A mattress was made and flame retardant evaluation was performed.

The results of Examples 30 to 36, Comparative Examples 38 to 44, and Comparative Examples 45 to 50 are shown in Table 9.

[0108] [Table 9] Table 9 (Flame shielding fabric that is knitted fabric)

[0109] As shown in Table 9, in Examples 30 to 36, the flame retardancy in the combustion test was good, and the overall judgment was acceptable. On the other hand, in Comparative Examples 38 to 44, since the thickness of the cloth covering the low-resilience urethane foam was insufficient, a hole was formed in the carbonized film, and the low-resilience urethane foam was ignited. Further, in Comparative Examples 45 and 46, since the amount of halogen-containing fiber (A) + flame-retardant cellulosic fiber (B) is small, the self-extinguishing performance is inferior and a hole is formed in the carbonized film, resulting in a low resilience urethane foam. Ignited. Further, in Comparative Examples 47 and 48, although there are many halogen-containing fibers (A) + flame-retardant cellulosic fibers (B), fire extinguishing ability is provided, but flame-retardant cellulosic fibers (B) + cellulosic fibers (C ) Is insufficient, the overall judgment that the carbonized film is considerably thin was rejected. In Comparative Examples 47 and 48, the hygroscopicity and the texture of the fabric were poor. Further, in Comparative Examples 49 and 50, since there were many polyester fibers (D), it was difficult to form a carbonized film and a hole was formed, and the low-resilience urethane foam was ignited.

Industrial applicability

[0110] The low resilience urethane foam material exhibits the unique flexibility and comfort, and the low resilience urethane foam covers the fabric to give the fabric a superior texture and feel. The flame retardant low-resilience urethane foam mattress of the present invention that is not damaged, comfortable and highly flame retardant is a so-called mattress that is used as a thickness and rug for mattresses and beds. Besides, it can be applied to a wide range of applications such as pillows and cushions, headboard cushions used for bed headboards, bed sofas, bedding products, interior textile products, and upholstered furniture products.

Claims

The scope of the claims

[1] A flame-retardant low-resilience urethane foam mattress obtained by coating a low-resilience urethane foam with a single layer or multiple layers of fabric,

At least one layer forces the halogen-containing fiber (A) 0 to 75 wt% of the fabric, flame retardant cell opening over scan fibers (B) 0 to 75 weight ^_0/0, cellulosic fibers (C) 0 to 75 wt% And polyester fiber (D) 0-30 wt% [(A) + (B) + (C) + (D)] = 100 wt%, 25 wt% ≤ [(A) + (B)] ≤ A flame-retardant low-resilience urethane foam mattress, which is a flame-shielding fabric composed of 75% by weight fibers, and the total thickness of the fabric covering the low-resilience urethane foam is 1.3 mm or more.

[2] The flame-retardant low-resilience urethane foam mattress according to claim 1, wherein the flame shielding fabric is composed of fibers satisfying 30% by weight ≦ [(B) + (C)].

[3] The flame-retardant low-resilience urethane foam mattress according to claim 1 or 2, wherein the flame-shielding fabric is composed of fibers having [(A) + (C) + (D)] = 100% by weight. .

[4] The flame-retardant low-resilience urethane foam mattress according to claim 3, wherein the flame-shielding fabric is composed of fibers of [(A) + (C)] = 100% by weight.

[5] The flame-retardant low-resilience urethane foam mattress according to claim 1 or 2, wherein the flame-shielding fabric is composed of fibers having [(B) + (C) + (D)] = 100% by weight. .

[6] The flame-retardant low-resilience urethane foam mattress according to claim 5, wherein the flame-shielding fabric is composed of fibers of [(B) + (C)] = 100% by weight.

[7] The flame-retardant low-resilience urethane foam mattress according to any one of claims 1 to 4, wherein the halogen-containing fiber (A) is modacrylic.

[8] Flame-retardant cellulosic fiber (B) Strength Fiber containing flame retardant in at least one fiber selected from the group strength consisting of cotton, hemp, rayon, polynosic, cuvula, acetate and triacetate The flame retardant low-resilience urethane foam mattress according to any one of claims 1, 2, 5 and 6.

[9] Flame retardant cellulosic fiber (B) force Rayon fiber containing 20 to 50% by weight of at least one selected from the group consisting of silicic acid and aluminum silicate as a flame retardant. Rebound urethane foam mattress.

[10] Flame retardant cellulose fiber (B) Strength Phosphate ester compound, halogen-containing phosphate ester compound, condensed phosphate ester compound, polyphosphate compound, red phosphorus, ammine compound, boric acid, At least one flame retardant selected from the group consisting of halogenated compounds, urea formaldehyde compounds, ammonium sulfate and guanidine condensate is added to cell-based fibers. The flame-retardant low-resilience urethane foam mattress according to claim 8, wherein the fiber is attached to ˜25 wt%.

[11] Cellulosic fiber (C) strength is at least one fiber selected from the group strength consisting of cotton, hemp, rayon, polynosic, cupra, acetate, and triacetate. Flame retardant low resilience urethane foam mattress.

12. The flame-retardant low-resilience urethane foam mattress according to claim 11, wherein the cellulosic fiber (C) is cotton fiber.

[13] The flame-retardant low-resilience urethane according to any one of claims 1 to 3, 5, and 7 to 12, wherein the polyester fiber is (D) force ordinary polyester fiber and Z or low-melting-point binder fiber. Foam mattress.

[14] A low-melting-point noinder fiber is selected from fibers composed of a single component of a low-melting polyester, a composite fiber composed of a normal polyester and a low-melting polyester, and a group strength composed of a composite fiber composed of a normal polyester and a low-melting polyolefin. The flame-retardant low-resilience urethane foam mattress according to claim 13, which is at least one kind of fiber.

[15] The flame-retardant low-resilience urethane foam mattress according to any one of claims 1 to 14, wherein the flame-shielding fabric contains 2 to 40% by weight of a flame retardant.

[16] The flame-retardant low-resilience urethane foam mattress according to any one of [1] to [15], wherein the flame-shielding fabric contains 2 to 20% by weight of an Sb compound.

[17] The flame-retardant low-resilience foam according to any one of claims 1 to 16, wherein the low-resilience urethane foam is covered with a flame-shielding fabric, which is a knitted fabric, and the outside thereof is further covered with a side fabric made of pile-shaped knitted fabric. Retin foam mattress.

[18] The flame-retardant low-resilience urethane foam mattress according to any one of [1] to [17], wherein the flame retardant fabric is a pile-shaped knitted fabric.

[19] Cellulosic fiber (C) or polyester fiber (D) as ground yarn for pile fabric The flame-retardant low-resilience urethane foam mattress according to claim 18, wherein:

[20] The flame-retardant low-resilience urethane foam mattress according to any one of claims 1 to 19, wherein the total weight of the fabric covering the low-resilience urethane foam is 300 gZm ² or more.