[0001] The present invention relates to an inexpensive and advanced flame resistant fiber
composite for furniture and beddings that can solve difficult problems for conventional
flame resistant fiber composites, that is, improved flame resistance of bedding products;
further improved processability and bulkiness; and satisfactory processability, touch,
feeling, and sensuousness, and to a fabric produced using the flame resistant fiber
composite.
BACKGROUND ART
[0002] Flame resistance is preferably given to materials used for furniture, beddings, etc.
in a house for prevention of fire. Since flammable materials, such as cotton and urethane
foams, are used for comfort in use of furniture or beddings, prevention of flaming
to the flammable materials over a long period of time is important for fire prevention.
In addition, the flame retardant materials to be used must not impair comfort or sensuousness
of the furniture or beddings in use. Although various flame resistant fibers and flame
retardants have so far been examined, materials fully having these advanced flame
resistance and requirements for materials for furniture and beddings have not yet
been realized.
[0003] A technique of coating of flame retardants to cotton cloths, that is, what is called
"additional processing flame retardation" is now being used, but there are problems,
such as in uniformity of application of flame retardants, hardening of cloth by means
of application, omission by washing, and safety of health. In addition, although it
is known that fabrics including fibers obtained using high polymers comprising copolymerized
halogen has outstanding sensuousness and flame resistance, they continue burning in
the case of power burner combustion and cannot maintain the structure thereof, and
as a result, they give inadequate fire-resistant performance for preventing flaming
to cotton and urethane foams that are used for the above-mentioned beddings and furniture.
[0004] Although cloths obtained from the heat-resistant fibers have outstanding flame resistance,
they have only poor power for preventing combustion of other non-flame resistant natural
fibers and chemical fibers, and therefore materials obtained from those materials
having been compounded only demonstrate inadequate flame resistance. Inevitably, there
arise problems that extremely expensive materials made only from heat-resistant fibers
can be used. In addition, heat-resistant fibers have problems of difficulty in production
of colored patterns having high sensuousness resulting from problems of unsatisfactory
processability at the time of filament opening, poor moisture absorptivity, or feeling
and poor dye affinity.
[0005] Japanese Patent Laid-Open No. 61-89339 proposes a flame resistant fiber composite
obtained by combination of an advanced flame resistant halogen containing fiber comprising
flame retardants added in large quantities, and a non-flame resistant other fiber,
as materials for improving the previously described disadvantages in furniture and
materials for beddings, and materials having touch, outstanding moisture absorptivity,
and outstanding feeling needed as general characteristics, and also having stable
flame resistance. Furthermore, Japanese Patent Laid-Open No. 8-218259 describes that
the technique can provide an advanced flame resistant fiber composite having outstanding
touch and outstanding moisture absorptivity, and advanced flame resistance by means
of mixing of a small amount of a heat-resistant fiber, that is, of mixing of halogen
atom and Sb compounds containing fiber that can be used for work uniform usage, and
cotton, etc. However, this technique has following problems as a flame resistant fiber
composite: difficulty in processing in manufacturing of nonwoven fabrics, and inadequate
bulkiness in a quilting process when using as a nonwoven fabric, in order to prevent
flaming to urethanes used for furniture or bedding products; problems in sensuousness
caused by poor feeling of gloss and poor coloring property resulting from inclusion
of fibers comprising a large quantity of added flame retardant; and inadequate fire-resistant
performance for preventing flaming to cotton and urethane foams used for the above-mentioned
beddings and furniture, in prolonged exposure to intense flame, while having self-extinguishing
property in case of a source of fire being kept away.
SUMMARY OF THE INVENTION
[0006] The present invention aims at improving difficult problems for conventional flame
resistant fiber composites to solve, that is, flame resistance of bedding products,
and at obtaining inexpensive and advanced flame resistant fiber composites used for
furniture and beddings, having more improved processability and bulkiness that found
in conventional products, satisfactory touch and feeling, and sensuousness.
[0007] As a result of wholehearted investigation performed by the present inventors for
solving the problems, it was found out that a flame resistant fiber composite having
outstanding sensuousness, touch, and feeling, and flame resistance of durability over
prolonged flaming might be obtained using a fiber composite obtained by mixing a fiber
consisting of a chlorine containing polymer, and an inflammable fiber comprising other
cellulosic fibers, to a heat-resistant fiber having poor ability for preventing combustion
of other inflammable fibers. In addition, it was also found out that problems of processability
or price as problems in independent use of heat-resistant fibers might also be improvable,
leading to completion of the present invention.
[0008] That is, the present invention relates to a flame resistant fiber composite obtained
by compounding so as to give 100 % by weight of a total amount of (A) to (D): 20 to
85 % by weight of a fiber (A) containing 0.5 to 50 parts by weight of an Sb compound
to 100 parts by weight of a polymer containing halogen atom of not less than 17% by
weight; 5 to 80 % by weight of a heat-resistant fiber (B); 0 to 40 % by weight of
a cellulosic fiber (C) ; and 0 to 40 % by weight of an inflammable fiber (D), such
as chemical fiber. In addition, the present invention also relates to a flame resistant
fiber composite, wherein the polymer containing halogen atom of the fiber (A) is a
copolymer comprising 30 to 70 % by weight of acrylonitrile, 70 to 30 % by weight of
a halogen atom containing vinyl based monomer, and 0 to 10 % by weight of a vinyl
monomer copolymerizable therewith; the heat-resistant fiber (B) is a fiber selected
from silicic acid containing cellulosic fibers, aramid fibers, and melamine fibers;
the cellulosic fiber (C) is a fiber without flame retarding treatment selected from
cotton, hemp, acetate based fibers, and rayon based fibers; and the inflammable fiber
(D), such as a chemical fiber, is at least one kind of fiber in polyester fibers and
nylon fibers.
[0009] In the above-described composite, for touch or moisture absorptivity, preferable
is a flame resistant fiber composite consisting of: 85 to 20 % by weight of the fiber
(A) containing 6 to 50 parts by weight of an Sb compound to 100 parts by weight of
the polymer containing halogen atom of not less than 17% by weight; 15 to 80 % by
weight of a silicic acid containing cellulosic fiber as the heat-resistant fiber (B);
and 0 to 40 % by weight of one or more kinds of chemical fibers as the inflammable
fiber (D), such as a chemical fiber, wherein the flame resistant fiber composite is
compounded so as to give contents of each fiber of (A) >= (D) or (B) >= (D), or a
flame resistant fiber composite obtained by compounding 85 to 20 % by weight of a
fiber (A) containing 6 to 50 parts by weight of an Sb compound to 100 parts by weight
of the polymer containing halogen atom of not less than 17% by weight; 5 to 40 % by
weight of the heat-resistant fiber (B); 5 to 40 % by weight of the cellulosic fiber
(C); and 5 to 40 % by weight of a polyester fiber as the inflammable fiber (D), such
as a chemical fiber. Moreover, for touch or sensuousness, preferable is a flame resistant
fiber composite consisting of: 30 to 70 % by weight of a fiber ,as the fiber (A),
containing 0.5 to 5.5 parts by weight of Sb to 100 parts by weight of a polymer containing
chlorine atom of not less than 25% by weight; 10 to 50 % by weight of the heat-resistant
fiber (B); 5 to 40 % by weight the cellulosic fiber (C) ; and 0 to 30 % by weight
of the inflammable fiber (D), such as a chemical fiber, wherein contents of fibers
(A) to (D) satisfy relationships of (1) (A) >= (D) ; (2) (A) + (D) is 50 to 90% by
weight; and (3) (C) + (D) is 30 to 60 % by weight.
[0010] Furthermore, the present invention relates to a fabric and nonwoven fabric produced
using the flame resistant fiber composite.
[0011] In a flame resistant fiber composite of the present invention, as the fiber (A),
used is a fiber containing 0.5 to 50 parts of an Sb compound to a polymer containing
halogen atom of not less than 17%, and used is a fiber containing 0.5 to 5.5 parts
by weight of an Sb compound to a polymer, as one example, containing chlorine atom
of not less than 25% by weight.
[0012] A lower limit value of a halogen atom content in the polymer containing halogen atom
of not less than 17% is preferably 20%, and more preferably 26%, and an upper limit
value is preferably 86% more preferably 73%, and especially preferably 48%. A halogen
content of less than 17% disadvantageously gives difficulty in rendering the fiber
flame resistant. A lower limit of chlorine content in the polymer containing chlorine
atom of not less than 25% by weight is preferably 26%, and an upper limit value is
preferably 73 % by weight, and especially preferably 48 to 58% by weight. A chlorine
content of less than 25% by weight disadvantageously gives difficulty in rendering
a fiber composite with inflammable fibers flame resistant.
[0013] The above-mentioned polymer containing halogen atom of not less than 17% includes,
for example, but not limited to, polymers of monomers containing halogen; copolymers
of the monomers containing halogen and monomers containing no halogen; mixtures of
polymers containing halogen and polymers containing no halogen; or halogen containing
polymer with halogen introduced during or after polymerization of monomers or polymers
containing no halogen.
[0014] Examples of such a polymer containing halogen atom of not less than 17% include,
for example, but not limited to: homopolymers of halogen atom containing vinyl based
monomers, such as vinyl chloride, vinylidene chloride, vinyl bromide, and vinylidene
bromide, or copolymers of two or more kinds thereof; copolymers of halogen atom containing
vinyl based monomers and acrylonitrile, such as, acrylonitrile-vinyl chloride, acrylonitrile-vinylidene
chloride, acrylonitrile-vinyl bromide, acrylonitrile-vinyl chloride-vinylidene chloride,
acrylonitrile-vinyl chloride-vinyl bromide, acrylonitrile-vinylidene chloride-vinyl
bromide; copolymers of one or more kinds of vinyl monomers including halogen, such
as vinyl chloride, vinylidene chloride, vinyl bromide, and vinylidene bromide, and
vinyl monomers copolymerizable with acrylonitrile and the vinyl monomers including
halogen; polymers obtained by adding or polymerizing halogen containing compounds
in acrylonitrile homopolymers; halogen containing polyesters etc. In addition, the
above-mentioned homopolymers and copolymers may be used in an appropriate combination.
[0015] Examples of the copolymerizable vinyl monomer include, for example: acrylic acid,
and esters thereof; methacrylic acid, and esters thereof; acrylamide; methacryl amide;
vinyl acetate; vinyl sulfonic acid, and salts thereof; methallyl sulfonic acid, and
salts thereof; styrene sulfonic acid, and salts thereof; 2-acrylamide-2-methylsulfonic
acid, and salts thereof. These may be used independently or two kinds or more may
be used in combination.
[0016] When the polymer containing halogen atom of not less than 17% is a polymer consisting
of 30 to 70% of acrylonitrile, 70 to 30% of a halogen containing vinyl based monomer,
and 0 to 10% of a vinyl monomer copolymerizable therewith, and preferably consisting
of 40 to 60% of acrylonitrile, 60 to 40% of a halogen containing vinyl based monomer,
and 0 to 10% of a vinyl monomer copolymerizable therewith, a fiber obtained advantageously
has excellent touch as found in acrylic fibers, while having desired performances
(strength, flame resistance, dye affinity, etc.). In addition, when at least one kind
of the copolymerizable vinyl monomer is a sulfonic group containing vinyl monomer,
dye affinity advantageously improves.
[0017] Examples of a copolymer containing units originated from the halogen containing vinyl
based monomer and acrylonitrile include, for example, a copolymer consisting of 50
parts of vinyl chloride, 49 parts of acrylonitrile, and 1 part of sodium styrene sulfonate;
a copolymer consisting of 43.5 parts of vinylidene chloride, 55 parts of acrylonitrile,
and 1.5 parts of sodium styrene sulfonate; a copolymer consisting of 41 parts of vinylidene
chloride, 56 parts of acrylonitrile, and 3 parts of sodium 2-acrylamide-2-methylsulfonate
etc.
[0018] Sb compounds used for the present invention are used as flame retardants, and examples
of the compounds include, for example, but not limited to, inorganic antimony compounds,
such as, antimony oxides (Sb
2O
3, Sb
2O
4, Sb
2O
5, etc.), antimonic acid and salts thereof, antimony oxychloride etc. These may be
used independently and may be used in combination of two or more kinds.
[0019] Moreover, a particle diameter of the Sb compound is preferably uniformly adjusted
to give not more than 2 micrometers, in order to avoid troubles, such as nozzle clogging
on a process for producing a fiber obtained by adding the Sb compound to a halogen
containing polymer, and to improve strength of the fiber, etc.
[0020] A percentage of the Sb compound to 100 parts by weight of the polymer containing
halogen atom of not less than 17% by weight is 6 to 50 parts, preferably 8 to 40 parts,
and more preferably 10 to 30 parts. In the case where the amount is less than 6 parts,
for obtaining flame resistance necessary as a flame resistant fiber composite, a mixing
percentage, in the flame resistant fiber composite, of a fiber (A) (hereinafter referred
to as fiber (A)) having the Sb compound contained in the polymer containing halogen
atom of not less than 17% is necessarily increased. In this case, however, characteristics
other than the flame resistance as a flame resistant fiber composite, for example,
excellent performances, such as touch, moisture absorptivity, and feeling, may be
hard to be obtained. When the amount exceeding 50%, on the other hand, induces nozzle
clogging at the process of fiber manufacturing, and impair of physical properties
of the fibers (strength, elongation, etc.), leading to disadvantageous problems in
respect of manufacturing, and quality of the fiber highly rendered flame resistant.
[0021] In the present invention, as long as an amount of the Sb compound to the polymer
containing halogen atom of not less than 17% is maintained to 6 to 50 parts, a combination
with other flame retardants may be used.
[0022] As other flame retardants usable in combination with the Sb compounds, for example,
include aromatic halogenated compounds, such as hexabromobenzene; aliphatic halogenated
compounds, such as chloroparaffins; halogen-containing phosphorus compounds, such
as tris(2,3-dicholoropropyl) phosphate; inorganic phosphorus compounds, such as ammonium
polyphosphate; inorganic magnesium compounds, such as MgO, Mg (OH)
2, and MgCO
3; and inorganic tin compounds, such as stannic oxide, stannic oxy-halides, stannous
hydroxide, ZnSnO
3, and ZnSn(OH)
6 etc. An amount of the other flame retardants used preferably is not less than 1 part
and not more than 10 parts to 100 parts by weight of the polymer containing halogen
atom of not less than 17% by weight. In addition, a total amount of the flame retardant
is not more than 50 parts to the polymer containing halogen atom of not less than
17%, and preferably not more than 40 parts, in consideration of troubles on manufacturing
process of the fiber and avoidance of physical properties impair as strength reduction
of fiber etc.
[0023] Sb compounds used for the polymer containing chlorine atom of not less than 25% by
weight in the fiber (A) is not especially limited. For improvement of flame resistance,
as the above-mentioned flame retardants, preferable are publicly known antimony oxides
(Sb
2O
3, Sb
2O
4, Sb
2O
5, etc.); antimonic acid and salts thereof; inorganic antimony compounds, such as antimony
oxychloide; inorganic magnesium compounds, such as MgO, Mg(OH)
2, and MgCO
3; and inorganic tin compounds, such as stannic oxide, stannic oxy-halides, and stannous
hydroxide. In order to give gloss, or coloring property in dyeing, and flame resistance
to fibers the compound having a particle diameter uniformly adjusted to not more than
2 micrometers is independently included, or in combination of two or more kinds thereof
in an amount of 0.5 to 5.5 parts by weight. For gloss or coloring property, the content
is preferably 0.5 to 3.5 parts by weight.
[0024] The fiber (A) containing 0.5 to 50 parts of the Sb compound to the polymer containing
halogen atom of not less than 17% may be used in either form of staple fiber, or filament,
and in case of processing in compounded form with the heat-resistant fiber (B), the
cellulosic fiber (C), and the inflammable fiber (D), such as chemical fiber, which
are used for the present invention, fibers having similar property to fibers to be
compounded are preferably selected. In accordance with heat-resistant fibers, natural
fibers and chemical fibers to be used for textiles usage, the staple fiber preferably
has a size of a fiber of 1.7 to 3.3 dtex, and a cut length of approximately 38 to
64 mm. However, in order to obtain a flame resistant fiber composite with bulkiness
or stiffness for usage of nonwoven fabrics etc., the staple fiber preferably has a
size of a fiber of 7.8 dtex to 12 dtex, and a cut length of approximately 51 to 102
mm.
[0025] The heat-resistant fiber (B) (hereinafter referred to as fiber (B)) used for the
present invention is a component is for formation of a backbone structure for maintenance
of a shape of the flame resistant fiber composite in burning of the inflammable component
in the flame resistant fiber composite. When the heat-resistant fiber (B) has a melting
point, the melting point is not less than 350 degrees C, and when it does not have
a melting point, the heat-resistant fiber (B) is a fiber having heat-resisting property
with a decomposition temperature of not less than 300 degrees C.
[0026] As examples of the fiber (B) include, for example, the fibers obtained from aromatic
polyamides, melamine, polyamidoimides, poly benzimidazoles, etc., silicic acid containing
fibers, phenolic fibers, carbon fibers, etc. and the fiber (B) may be used independently
and two or more kinds may be used in combination.
[0027] Examples of the aromatic polyamide fiber include, for example, para-aromatic polyamide
fibers having a degradation starting temperature of not less than 450 degrees C (for
example, Kevlar manufactured by E. I. du Pont de Nemours & Co.), Technora manufactured
by Teijin, Ltd., Twaron manufactured by Teijin Twaron B.V. etc.; meta aromatic polyamide
fibers having a decomposition temperature of about 550 degrees C (for example, Nomex
manufactured by E. I. du Pont de Nemours & Co.), Conex manufactured by Teijin, Ltd.,
and Apyeil manufactured by Unitika, Ltd. etc. Examples of the melamine fibers, for
example, include a melamine fiber Basofil having a degradation starting temperature
of approximately 370 degrees C manufactured by Basofil Fibers etc.
In addition, examples of the polyamidoimide fibers include a polyamidoimide fiber
(for example, Kermel manufactured by Rhone Poulenc) having a degradation starting
temperature of approximately 380 degrees C etc. Furthermore, examples of the poly
benzimidazole fibers include a poly benzimidazole fiber (for example, PBI manufactured
by Celanese etc.) having a degradation starting temperature of approximately 450 degrees
C. Examples of the phenolic fibers include novoloid fibers (for example, Kynol manufactured
by Kynol com. etc.) having a degradation starting temperature of approx1 370 degrees
C. Examples of the silicic acid containing cellulosic fibers include, for example,
Visil containing approximately 30% of silicic acid manufactured by SATERI INTERNATIONAL.
The silicic acid containing cellulosic fiber used for the present invention is a component
used for improvement of flame resistance and maintenance of strength of fabrics of
the flame resistant fiber composite, and is a component effective for formation of
carbonized films in combustion while giving outstanding comfortable properties, such
as touch and moisture absorptivity. The fiber is cellulose fibers containing 20 to
50% of silicic acid therein, and usually has a size of a fiber of about 1.7 to 8 dtex,
and a cut length of approximately 38 to 128 mm.
[0028] The cellulosic fiber (C) used for the present invention (hereinafter referred to
as fiber (C)) is a component for giving outstanding comfortable properties, such as
touch and moisture absorptivity, to the flame resistant fiber composite of the present
invention. Furthermore, the fiber (C) is a component for carbonizing, and forms carbonized
materials hardly being decomposed by high temperatures in the flame resistant fiber
composite, in combustion together with the polymer containing halogen atom (A).
[0029] Examples of the fiber (C) include fibers, such as cotton, hemp, acetate fibers, and
rayon, and these may be used independently and two or more kinds may be used in combination.
[0030] Examples of the inflammable fiber (D), such as a chemical fibers (hereinafter referred
to as fiber (D)) include synthetic fibers, such as semi-synthetic fibers, such as
promix, polyester fibers, nylon fibers, acrylic fibers etc., and these may be used
independently and two or more kinds may be used in combination. Fusible fibers, such
as the polyester fibers and nylon fibers, are preferable among them. Polyester fibers
and nylon fibers form fused materials in combustion, and the fused material covers
the flame resistant fiber composite, and increases strength of the carbonized film
formed from the flame resistant fiber composite. Thereby the polyester fibers and
nylon fibers can advantageously attain fire-resistant performance for preventing flaming
to the cotton and urethane foam to be used for beddings or furniture, also in the
case where the flame resistant fiber composite is exposed to intense flame for a prolonged
period of time. The reason is believed that the fused material formed by these fibers
in combustion process permeates into the flame resistant fiber composite to fill openings
between fibers, and to strengthen structures thereof. Polyester fibers have a high
softening point and a high melting point, and improve still more preferably the heat-resisting
property of the flame resistant fiber composite among them.
Furthermore, polyester fibers have low cost and strong stiffness; this strong stiffness
may easily give bulkiness when processed into nonwoven fabrics, resulting in excellent
sensuousness when processed into quilted products. For example, the polyester fibers
advantageously can give excellent looks, bulkiness, touch, etc. after finished into
beds mats, bed pads, etc.
[0031] In the present invention, 100 % by weight of the flame resistant fiber composite
of the present invention are produced from: 85 to 20 parts of the fiber (A) ; 15 to
80 % by weight of a silicic acid containing cellulosic fiber as the fiber (B); and
0 to 40 % by weight of the fiber (D) in case of 2 to 3 component system according
to claim 8. A blending ratio of the above-described fibers may be determined according
to quality, such as water absorptivity, touch, moisture absorptivity, feeling, sensuousness,
product strength, washing resistance, and durability, as well as flame resistance
necessary for final products produced from the flame resistant fiber composite obtained.
In general, the component fibers are compounded so as to give 100 % by weight of a
sum total of: 85 to 20 % by weight of the fiber (A), and preferably 75 to 25 % by
weight ; 15 to 80 % by weight of the silicic acid containing cellulose fiber, and
preferably 20 to 70 % by weight ; and 0 to 40 % by weight of the fiber (D), and preferably
5 to 35 % by weight.
[0032] An amount of the fiber (A) less than 20 % by weight gives unsatisfactory flame resistance
to the flame resistant fiber composite obtained. On the other hand, an amount exceeding
80 % by weight gives outstanding flame resistance, but decreases a ratio of the silicic
acid containing cellulose fiber as the fiber (B), resulting in insufficient fire-resistant
performance for preventing flaming to cotton and urethane foams to be used for beddings
or furniture in prolonged exposure to intense flame.
[0033] In addition, an amount of the fiber (D) exceeding 40 % by weight relatively decreases
amounts of the fiber (A) and the fiber (B), and gives inadequate flame resistance.
[0034] In addition, an amount of the silicic acid containing cellulose fiber as the fiber
(B) of less than 15 % by weight, impairs fire-resistant performance for preventing
flaming to cotton and urethane foams to be used for beddings or furniture in prolonged
exposure to intense flame. On the other hand, an amount exceeding 80 % by weight decreases
a percentage of the fiber (A) to give inadequate flame resistance.
[0035] Reasons for the flame resistant fiber composite of the present invention to show
excellent flame resistance is probably that combustion suppression effect of halogenated
Sb compounds formed by the fiber (A), and formation effect of carbonized films of
a composite by the silicic acid containing cellulose fiber as the fiber (B) are synergistically
demonstrated during combustion, and that furthermore, the fiber (D) fuses in combustion
and covers the flame resistant fiber composite to make more stable carbonized films
formed from the flame resistant fiber composite, providing fire-resistant performance
for preventing flaming to cotton and urethane foams to be used for beddings or furniture
in prolonged exposure to intense flame. Thereby, flame resistance excellent greater
than expectation may be demonstrated.
[0036] Although the silicic acid containing cellulose fiber as the fiber (B) is originally
a fiber that cannot easily flame, it has poor ability for rendering other inflammable
fiber flame resistant. Therefore, rendering the fiber (D) flame resistant by means
of compounding of the fiber (B) and the fiber (D) will not be successful. Prominent
effect may be obtained only by compounding fibers as in the present invention.
[0037] In the present invention, 100 % by weight of the flame resistant fiber composite
of the present invention are produced from: 80 to 20 % by weight of the fiber (A);
5 to 40 % by weight of the fiber (B); 5 to 40 % by weight of the fiber (C); 5 to 40
% by weight of a polyester fiber as the fiber (D) in case of 4 component system according
to claim 11. A blending ratio of the above-mentioned fibers may be determined according
to quality, such as water absorptivity, touch, moisture absorptivity, feeling, sensuousness,
product strength, washing resistance, and durability, as well as flame resistance
necessary for final products produced from the flame resistant fiber composite obtained.
The component fibers are compounded to give 100 % by weight of a sum total of: 80
to 20 % by weight of the fiber (A), and preferably 60 to 30 % by weight; 5 to 40 %
by weight of the fiber (B), and preferably 10 to 35 % by weight; 5 to 40 % by weight
of the fiber (C), and preferably 10 to 35 % by weight; and 5 to 40 % by weight of
a polyester fiber as the fiber (D), and preferably 10 to 35 % by weight.
[0038] An amount of the fiber (A) less than 20 % by weight gives unsatisfactory flame resistance
to the flame resistant fiber composite obtained. On the other hand, an amount exceeding
80 % by weight gives outstanding flame resistance, but decreases a percentage of the
fiber (B) and the fiber (C), resulting in insufficient fire-resistant performance
for preventing flaming to cotton and urethane foams to be used for beddings or furniture
in prolonged exposure to intense flame.
[0039] In addition, an amount of the polyester fiber as the fiber (D) of less than 5 % by
weight gives unsatisfactory processability, bulkiness, touch, feeling, etc., and an
amount exceeding 40 % by weight relatively decreases amounts of the fiber (A), the
fiber (B), and the fiber (C), and gives inadequate flame resistance.
[0040] An amount of the fiber (B) of less than 5 % by weight impairs fire-resistant performance
for preventing flaming to cotton and urethane foams to be used for beddings or furniture
in prolonged exposure to intense flame, demonstrating inadequate improvement in flame
resistant effect. On the other hand, an mount exceeding 40 % by weight gives only
flame resistant fiber composite having poor processability, touch, and sensuousness
as a disadvantage of heat-resistant fibers.
[0041] Furthermore, an amount of a cellulosic fiber as the fiber (D) of less than 5 % by
weight gives unsatisfactory water absorptivity, touch, dissatisfied moisture absorptivity,
feeling, etc., and moreover cannot give sufficient improvement effect in flame resistance
by means of carbonized film formation. On the other hand, an mount exceeding 40 %
by weight relatively decreases an amount of the fiber (A) and the fiber (B), and impairs
fire-resistant performance for preventing flaming to cotton and urethane foams to
be used for beddings or furniture in prolonged exposure to intense flame, resulting
in inadequate flame resistance.
[0042] Reasons for the flame resistant fiber composite of the present invention to show
excellent flame resistance is probably that combustion suppression effect of halogenated
Sb compounds formed by the fiber (A), carbonized film formation effect of the composite
by the fiber (B), and carbonized film formation effect by carbonization in concurrent
combustion of the fiber (C) and the fiber (A) are synergistically demonstrated during
combustion, and that furthermore, a polyester fiber as the fiber (D) fuses in combustion
and covers the flame resistant fiber composite to make more stable carbonized films
formed from the flame resistant fiber composite, providing fire-resistant performance
for preventing flaming to cotton and urethane foams to be used for beddings or furniture
in prolonged exposure to intense flame. Thereby, flame resistance excellent greater
than expectation may be demonstrated.
[0043] Although the fiber (B) is originally a fiber that cannot easily flame, it has poor
ability for rendering other inflammable fiber flame resistant. Therefore, rendering
the fiber (D), and the fiber (D) flame resistant by means of compounding only of the
fiber (B) and fiber (D) or compounding only of the fiber (B) and the fiber (C) will
not be successful. Prominent effect may be obtained only by compounding fibers as
described in the present invention.
[0044] In the present invention, in case of 2 to 4 component system according to Claim 12,
a flame resistant fiber composite of the present invention is produced to give 100
% by weight of a sum total of: 30 to 80 % by weight of the fiber (A) containing 0.5
to 5.5 parts by weight of the Sb compound to a polymer containing chlorine of not
less than 25% by weight as the fiber (A) ; 10 to 50 % by weight of fiber (B); 5 to
40 % by weight of fiber (C) ; and 0 to 30 % by weight of fiber (D), and to satisfy
relationships of contents of each fiber in the flame resistant fiber composite of
(A) >= (C), and (A) + (C) to be 50 to 90 % by weight, and (B) + (C) to be 30 to 60
% by weight. A blending ratio of the above-mentioned fibers may be determined according
to quality, such as sensuousness, water absorptivity, touch, moisture absorptivity,
feeling, product strength, washing resistance, and durability, as well as flame resistance
necessary for final products produced from the flame resistant fiber composite obtained.
In general, the component fibers are compounded to give a sum total of 100 % by weight
of: 30 to 80 % by weight of a fiber containing 0.5 to 5.5 parts by weight of Sb compound
to a polymer containing chlorine of not less than 25% by weight as fiber (A), and
preferably 35 to 55 % by weight; 10 to 50 % by weight of the fiber (B), and preferably
15 to 45 % by weight; 5 to 40 % by weight of the fiber (C), and preferably 10 to 35
% by weight; and 0 to 30 % by weight of fiber (D), and preferably 0 to 25 % by weight,
more preferably 0 to 15 % by weight, and to satisfy relationships of contents of each
fiber in the flame resistant fiber composite of (A) >= (C) and (A) + (C) to be 50
to 90 % by weight, and (B) + (C) to be 30 to 60 % by weight.
[0045] An amount of less than 30 % by weight of a fiber containing 0.5 to 5.5 parts by weight
of the Sb compound to a polymer containing chlorine of not less than 25% by weight
as the fiber (A) only gives inadequate ability for preventing combustion of the fiber
(C) and the fiber (D), resulting in unsatisfactory flame resistance of the flame resistant
fiber composite to be obtained. On the other hand, an amount exceeding 80 % by weight
gives excellent flame resistance of the flame resistant fiber composite itself, but
relatively decreases a component for forming a skeleton to maintain a shape in the
flame resistant fiber composite in combustion. As a result, for example, performance
for preventing flaming to flammable materials, such as urethane foams used for chairs
or mattress, and touch, moisture absorptivity, etc. will be unsatisfactory.
[0046] In order to prevent combustion of the fiber (C) and the fiber (D), an amount of the
fiber containing 0.5 to 5.5 parts by weight of the Sb compound to a polymer containing
chlorine of not less than 25% by weight as the fiber (A) is preferably 40 to 80 %
by weight.
[0047] In addition, an amount of the fiber (B) of less than 10 % by weight cannot give sufficient
fire-resistant effect having durability to flame for a long time. On the other hand,
an amount exceeding 50 % by weight gives the flame resistant fiber composite with
only unsatisfactory touch and sensuousness as a disadvantage of usual heat-resistant
fibers.
[0048] An amount of the fiber (C) of less than 5 % by weight gives inadequate amount of
component for forming carbonized materials, while giving unsatisfactory touch, moisture
absorptivity, etc., leading to insufficient fire-resistant effect having durability
to flame for a long time. On the other hand, an amount exceeding 40 % by weight increases
inflammable components in the flame resistant fiber composite, resulting in inadequate
flame resistance. An amount of less than 55 % by weight of a total amount of a fiber
containing 0.5 to 5.5 parts by weight of the Sb compound to a polymer containing chlorine
of not less than 25% by weight as the fiber (A), and of the fiber (B) needs an amount
of the fiber (C) of preferably 30 to 40 % by weight, in order to form a sufficient
amount of carbonized materials in the flame resistant fiber composite in combustion.
[0049] Furthermore an amount of the fiber (D) exceeding 30 parts by weight also increases
inflammable components in the flame resistant fiber composite, and impairs flame resistance.
[0050] In addition, an amount of the fiber containing 0.5 to 5.5 parts by weight of the
Sb compound to a polymer containing chlorine of not less than 25% by weight as the
fiber (A) is smaller than that of the fiber (C) in the flame resistant fiber composite,
inadequate amount of formation of carbonized materials occurs, leading to decrease
in fire-resistant effect with durability to flaming for a long time.
[0051] In addition, when a total amount of the fiber containing 0.5 to 5.5 parts by weight
of the Sb compound to a polymer containing chlorine of not less than 25% by weight
as the fiber (A), and an amount of fiber (C) is less than 50 % by weight in the flame
resistant fiber composite, shortage of components forming carbonized materials does
not allow sufficient demonstration of fire-resistant effect with durability to flaming
for a long time, resulting in inadequate touch. On the other hand, the above-mentioned
amount exceeding 90 % by weight gives inadequate amount of the fiber (B), leading
to insufficient flame resistant effect. Furthermore, when a total amount of the fiber
(B) and an amount of the fiber (C) is less than 30 % by weight, an amount of components
for maintaining a structure in the flame resistant fiber composite in combustion is
decreased, leading to inadequate fire-resistant effect. On the other hand, an amount
exceeding 60 % by weight relatively decreases, to a total amount of the fiber (B)
and amount of fiber (C), a percentage of the fiber containing 0.5 to 5.5 parts by
weight the Sb compound to a polymer containing chlorine of not less than 25% by weight
as the fiber (A), and does not allow sufficient formation of structures having durability
to flaming for a long time.
[0052] Reasons for demonstration of excellent flame resistance in the flame resistant fiber
composite of the present invention are considered as follows. When, during combustion,
the flame resistant fiber composite is heated and reaches temperature conditions causing
combustion, a fiber containing 0.5 to 5.5 parts by weight of the Sb compound to a
polymer containing chlorine of not less than 25% by weight as the fiber (A) will discharge
active chlorine radical and hydrogen chloride to catch the active radical that derives
chain reactions of combustion of the flame resistant fiber composite. There will synergistically
be demonstrated the above-described combustion suppression effect for cutting combustion
chain reactions, subsequent acceleration of dehydration carbonization, forming carbonized
materials with difficulty in decomposition even at elevated temperatures by the fiber
(c) and also improved effects of heat-resistance in the composite by the fiber(B).
Thereby, flame resistance excellent greater than expectation may be demonstrated.
[0053] Although the fiber (B) is a fiber that originally cannot easily flame, it has poor
ability to give flame resistance to the other fiber (C), and therefore compounding
of the fiber (B) with the fiber (C) may not give flame resistance to the fiber (C).
And therefore, remarkable effect of rendering other fibers flame resistant will be
obtained only by compounding of the fibers as described in the present invention.
[0054] Furthermore, use of at least one kind of fusible fibers, such as polyester fibers
and nylon fibers as the fiber (D) will make fused materials formed in combustion process
permeate into the flame resistant fiber composite, and fill space between fibers to
form a firm structure. Thereby flame resistance of the flame resistant fiber composite
will be improved. In addition, use of antimony oxide in the fiber containing 0.5 to
5.5 parts by weight of the Sb compound to the polymer containing chlorine of not less
than 25% by weight as the fiber (A) will make chlorine compounds react with antimony
oxide at high temperatures to form volatile antimony chloride, and the volatile antimony
chloride will stay in the reaction system for a long time, and will work as an effective
active radical scavenger because of heavier property than of air.
[0055] A flame resistant fiber composite of the present invention may be obtained by compounding
of the above-described fiber (A), (B), (C), and (D), and may be in forms of fabrics,
such as textiles, knittings, and nonwoven fabrics; assembled items of fibers, such
as slivers and webs; yarn-like materials, such as spun yarns, ply yarns, twisted yarns;
and string-like materials, such as knit strings and plaited cords.
[0056] The above-described "compounding" means a process for obtaining fabrics etc. including
each fiber at predetermined ratios, by mixing of fiber (A), (B), (C), and (D) using
various methods, and also means combining each fiber and yarn in stages of blending,
spinning, twisting, weaving and knitting.
[0057] A flame resistant fiber composite of the present invention may include antistatic
agents, agents for prevention of coloring by heat, light resistance improvers, whiteness
improver, matting inhibitors, etc. if necessary.
[0058] Thus obtained flame resistant fiber composite of the present invention has desired
flame resistance, and has characteristics excellent in touch, feeling, moisture absorptivity,
sensuousness, etc.
[0059] When the above-mentioned fibers (A), (B), (C), and (D) are in a shape of staple fibers,
a flame resistant fiber composite of the present invention may be manufactured in
following methods by: spinning after blending of the fibers; manufacturing yarns and
sliver and subsequent twisting thereof ; wrapping of two kinds of spun yarns around
one kind of the sliver; and wrapping of one kind of the spun yarn around a sliver
obtained by blending two kinds. The composite may be manufactured by combination of
the methods.
[0060] And when the above-mentioned fibers (A), (B), (C), and (D) are in a form of filament,
a flame resistant fiber composite of the present invention may be manufactured in
following methods by: twisting of each filament; twisting of two kinds of filaments
around one kind of filament, respectively; twisting of one kind of filament to a filament
obtained by twisting of two kinds of filaments; and twisting of a filament obtained
by twisting of two kinds of filaments to one kind of filament. The composite may be
manufactured by combination of the methods.
[0061] Furthermore, when a part in the above-mentioned fibers (A), (B), (C), and (D) is
in a form of a staple fiber, and remainder is in a form of a filament, the composite
may be manufactured in a method that a component of a staple fiber is blended with
other component fiber(s) to obtain a spun yarn, and the spun yarn may be twisted with
other component filament(s).
[0062] When a fabric is manufactured using the flame resistant fiber composite of the present
invention, the fabrics has characteristics, such as outstanding flame resistance,
touch, feeling, moisture absorptivity, sensuousness, etc. originated in the flame
resistant fiber composite of the present invention.
[0063] The above-described "fabric" comprises textiles, knittings, nonwoven fabrics, and
strings, and the "fabric" may be advantageously used not only in garments, such as
fire-resistant work uniforms, but in interior designed products, such as curtains
and carpets, beddings, such as sheets, blankets, bed mats, and bed pads etc. and moreover
in applications that need general fiber characteristics and advanced flame resistance
and also that need excellent touch, moisture absorptivity, feeling, and sensuousness.
[0064] Special methods are not necessary for manufacturing these fabrics, and conventional
processes generally used may be used without any special techniques.
BEST MODE FOR CARRYING-OUT OF THE INVENTION
[0065] The present invention will, hereinafter, be described in more detail, with reference
to Examples, but the present invention is not limited only to the Examples. The fibers
were measured for flame resistance in Examples as follows in a form of a nonwoven
fabric.
(Preparation of a nonwoven fabric for combustion test)
(1) Sample nonwoven fabric
[0066] Sample nonwoven fabric with a weight of 200 g/m
2 and a dimension of 30 cm length and 45 cm width was prepared by needle punch method
using a fiber mixed at a predetermined percentage.
(2) Nonwoven fabric for coverings
[0067] Sample polyester nonwoven fabric for coverings with a weight of 200 g/m
2 and a dimension of 30 cm length and 45 cm width was prepared by needle punch method
using a fiber mixed at a predetermined percentage in a same manner.
(Preparation of a sample for combustion test)
[0068] A simple mattress was made and was used as a sample for combustion test. The sample
nonwoven fabric (1) was layered on the polyester nonwoven fabric for covering (2),
and a textile fabric made of a polyester (weight 120 g/m
2) as a surface fabric was further layered on the above-described layered fabrics to
obtain a three-layered structure. The three-layered structure obtained was quilted
using a cotton thread, and furthermore was fixed onto a polyurethane foam (Type 360S
by Toyo Tire & Rubber CO. LTD.) having a dimension with 30 cm of a length, 45 cm of
a width, and 7.5 cm of a thickness, and a density of 22 kg/m
3, using staplers.
(Combustion test method)
(1) Burner shape
[0069] The burner head has a shape of character of T, and the burner head was made by a
stainless steel having an outside diameter of 1.27 cm, and a thickness of 0.0889 cm.
A portion of a bar of a character of T has a length of 30.48 cm, an uppermost surface
for the bar part of character of T has 34 openings (perforation out of which gas comes)
of 1.2 mm in a diameter at equal intervals.
(2) Combustion test method
[0070] A sample for combustion test was disposed so as to show an upper surface side of
a three-layered structure. The burner head was disposed in a center of the sample,
and in parallel to a longitudinal direction of the sample, when observed in an upper
surface of the sample, so that a face of perforation to blow out flame might give
a height of 42 mm in an upper part of the sample, and that a horizontal bar of character
of T might horizontally extend, and a vertical bar might extend in a vertical and
upper direction. As combustion gas, propane (99% or more of purity) was used, and
conditions for gas pressure of 0.11 MPa, a gas mass flow of 12.9 L/min, and a flaming
period 70 seconds were adopted. Existence of firing to urethane foam at this time,
a state of the sample nonwoven fabric, and combustion of surface fabric were evaluated.
A case where the urethane foam did not have firing at this time was evaluated as A,
and a case having firing as C. In a state of carbonized films of a sample nonwoven
fabric, a case where the carbonized films of the sample nonwoven fabric did not have
penetrated perforations, and a case where it did not have cracks were evaluated as
A, and a case where it had perforations and cracks was evaluated as C after termination
of the combustion test. In combustion of a surface fabric, a case where self-extinguishing
occurred promptly within 30 seconds was evaluated as A after termination of flaming
by a burner, and a case where combustion continued as C. In flame resistant evaluation,
a case where A was given for all of the three items was evaluated as A, and a case
where one or more items of C were given was evaluated as C.
(Sensual evaluation result)
(Bulkiness of sample nonwoven fabric)
[0071] In order to evaluate processability of the flame resistant fiber composite nonwoven
fabric, sensual evaluation was performed about voluminous touch of fabrics in quilting
process.
[0072] Evaluation was performed by visual method, and a level where a front fabric in quilting
process had voluminous touch preferable as a nonwoven fabric for beddings was evaluated
as A (for example, a nonwoven fabric using polyester fibers), a level suitable for
use as B, a level inferior to B was evaluated as C (for example, a nonwoven fabric
using rayon fibers.)
(Evaluation method of characteristic of a cellulose fiber)
[0073] Examined was by sensual evaluation whether a flame resistant fiber composite had
characteristic (visual appreciation, feeling) as a cellulosic fiber. Evaluation A
shows that the flame resistant fiber composite has characteristics (visual appreciation,
feeling) of cellulosic fiber, and evaluation C shows that the flame resistant fiber
composite does not have them.
(Evaluation method of whiteness of a sample nonwoven fabric)
[0074] In order to evaluate sensuousness of nonwoven fabric of a flame resistant fiber composite,
whiteness of the sample nonwoven fabric was evaluated by sensual method. Sensuous
evaluation was performed based on visual viewpoint, and a level suitable for use in
usage of upholstered furniture surface fabrics, where gloss and coloring property
were required, was evaluated as A, and an unsuitable level as C.
(Evaluation method of touch)
[0075] Sensual evaluation was performed about touch and feeling, especially feeling of dry
touch, of a flame resistant fiber composite nonwoven fabric. Evaluation was performed
in a manner that a preferable level or usable level in usage of a front side of upholstered
furniture was evaluated as A (for example, nonwoven fabric using polyester fiber),
and a level inferior to the above-mentioned level was evaluated as C (for example,
nonwoven fabric using melamine fiber.)
(Evaluation method of sensuousness (feeling of gloss, coloring property))
[0076] In order to evaluate sensuousness of a flame resistant fiber composite nonwoven fabric,
sensual evaluation was performed, respectively about feeling of gloss, and coloring
property after dyeing of the sample nonwoven fabric. Sensuous evaluation was carried
out from visual viewpoint. In gloss, a level suitable for use in front fabric usage
of upholstered furniture was evaluated as A, and an unsuitable level was evaluated
as C. In coloring property, a level suitable for use to coloring property needed in
front fabric usage of upholstered furniture was evaluated as A, and an unsuitable
level was evaluated as C. Dyeing was performed under following conditions: cationic
dyestuffs (Maxilon Yellow 2RL 0.55% omf, Maxilon Red GRL 0.25% omf, Maxilon Blue GRL
0.30% omf: all manufactured by Ciba-Geigy), acetic acid, sodium acetate, and anionic
dispersant 2%omf (LevenolWX: manufactured by Kao Corp.) as an auxiliary agent, an
accelerating agent 0.4% omf (sodium lauryl sulfate), liquor ratio 1 : 2.5, and boiled
at normal pressure for 1-hour. After dyeing, the sample was dehydrated by a centrifugal
dehydrator, and dried at ordinary temperature to obtain a nonwoven fabric having dark
brown hue.
(Manufacturing Example 1)
[0077] A copolymer comprising 51% by weight of acrylonitrile, 48% by weight of vinylidene
chloride, and 1% by weight of p-sodium styrene sulfonate was dissolved so that a resin
concentration might give 30% by weight into dimethylformamide. Antimony trioxide 15
parts was added to 100 parts of a resin weight of the obtained resin solution to obtain
a spinning solution.
[0078] The antimony trioxide had a particle diameter uniformly adjusted to not more than
2 micrometers, and was beforehand adjusted so that it might disperse uniformly in
a diluting resin solution.
[0079] A spinning solution including antimony trioxide was extruded into an dimethylformamide
aqueous solution with a concentration of 50% by weight, using a nozzle having a diameter
of nozzle hole of 0.08 mm, and a number of holes of 300 holes. The obtained fiber
was dried at 120 degrees C after washing with water, subsequently, after drawing at
3 times, heat treatment was given at 145 degrees C for 5 minutes to obtain a fiber
(A).
[0080] A chlorine content of the obtained fiber gave 35.1% by weight to a weight of a chlorine
containing copolymer. A staple fiber having a size of a fiber of 2.2 dtex, a strength
of 2.5 cN/dtex, an elongation ratio of 40%, and a cut length of 51 mm was obtained.
(Manufacturing Example 2)
[0081] A copolymer comprising 56% by weight of acrylonitrile, 41% by weight of vinylidene
chloride, and 3% by weight of sodium 2-acrylamide-2-methylpropanesulfonate was dissolved
into dimethylformamide so that a resin concentration might give 20% by weight. Antimony
trioxide was added into the obtained resin solution to give a spinning solution. Table
1 shows amounts of addition of antimony trioxide.
[0082] The antimony trioxide had a particle diameter uniformly adjusted to not more than
2 micrometers, and was beforehand adjusted so that it might disperse uniformly in
a diluting resin solution.
[0083] A spinning solution including antimony trioxide was extruded into an dimethylformamide
aqueous solution with a concentration of 50% by weight using a nozzle having a diameter
of nozzle hole of 0.08 mm, and a number of holes of 300 holes. The obtained fiber
was dried at 120 degrees C after washing with water, and subsequently, after drawing
at 3 times, heat treatment was given at 145 degrees C for 5 minutes to obtain a fiber
(A).
[0084] A chlorine content of the obtained fiber gave 30.0% by weight to a weight of a chlorine
containing copolymer. A staple fiber having a size of a fiber of 2.2 dtex, strength
of 2.9 cN/dtex, an elongation ratio of 38%, and a cut length of 51 mm was obtained.
(Examples 1 to 7 and Comparative Examples 1 to 14)
[0085] Blended at percentages shown in Table 1 were the Fiber (A) obtained by Manufacturing
Example 1; Basofil of a melamine fiber (having a distribution of a size of a fiber
of approximately 1 to 3.5 dtex, and distribution of 20 to 200 mm of cut length, manufactured
by Basofil Fibers), Visil as a silicon containing cellulosic fiber (1.7 dtex, 40 mm
of a cut length, manufactured by SATERI INTERNATIONAL), and Technora (1.7 dtex, 38
mm of a cut length, manufactured by Teijin Ltd.) of a para-aromatic polyamide fiber
as the fiber (B); a rayon (1.5 dtex, 38 mm of a cut length) as the cellulosic fiber
(C); and a polyester fiber (6.6 dtex, 51 mm of a cut length) as the fiber (D), and
sample nonwoven fabrics were manufactured. These samples were used for combustion
test. Table 2 shows evaluation results.
Table1
Example number |
Blending ratio in a flame resistant fiber composite (% by weight) |
Fiber (A) |
Fiber (B) |
Fiber (C) |
Fiber (D) |
Melamine fiber |
Silicic acid containing cellulose fiber |
Aromatic polyamide fiber |
1 |
55 |
15 |
0 |
0 |
15 |
15 |
2 |
45 |
15 |
0 |
0 |
15 |
25 |
3 |
35 |
35 |
0 |
0 |
15 |
15 |
4 |
35 |
15 |
0 |
0 |
35 |
15 |
5 |
35 |
15 |
0 |
0 |
15 |
35 |
6 |
35 |
0 |
15 |
0 |
15 |
35 |
7 |
35 |
0 |
0 |
15 |
15 |
35 |
Comparative Example 1 |
100 |
0 |
0 |
0 |
0 |
0 |
" 2 |
0 |
0 |
0 |
0 |
0 |
100 |
" 3 |
0 |
100 |
0 |
0 |
0 |
0 |
" 4 |
0 |
0 |
0 |
0 |
100 |
0 |
" 5 |
50 |
0 |
0 |
0 |
0 |
50 |
" 6 |
50 |
0 |
0 |
0 |
50 |
0 |
" 7 |
0 |
50 |
0 |
0 |
0 |
50 |
" 8 |
0 |
0 |
0 |
0 |
50 |
50 |
" 9 |
0 |
50 |
0 |
0 |
50 |
0 |
" 10 |
50 |
0 |
5 |
0 |
45 |
0 |
" 11 |
45 |
0 |
10 |
0 |
45 |
0 |
" 12 |
35 |
0 |
20 |
0 |
45 |
0 |
Table2
Example number |
Combustion test result |
Sensual evaluation result |
Existence of urethane combustion |
Perforation of sample nonwoven fabric |
Surface fabric combustion |
Flame resistant result |
Sample nonwoven fabric bulkiness |
Characteristic of cellulosic fiber |
1 |
A |
A |
A |
A |
B |
A |
2 |
A |
A |
A |
A |
A |
A |
3 |
A |
A |
A |
A |
B |
A |
4 |
A |
A |
A |
A |
B |
A |
5 |
A |
A |
A |
A |
A |
A |
6 |
A |
A |
A |
A |
A |
A |
7 |
A |
A |
A |
A |
A |
A |
Comparative Example 1 |
C |
C |
A |
C |
C |
C |
" 2 |
C |
C |
C |
C |
A |
C |
" 3 |
A |
A |
C |
C |
C |
C |
" 4 |
C |
C |
C |
C |
C |
A |
" 5 |
C |
C |
A |
C |
A |
C |
" 6 |
C |
C |
A |
C |
C |
A |
" 7 |
A |
A |
C |
C |
A |
C |
" 8 |
C |
C |
C |
C |
A |
A |
" 9 |
A |
A |
C |
C |
C |
C |
" 10 |
C |
C |
A |
C |
C |
A |
" 11 |
A |
A |
A |
A |
C |
A |
" 12 |
A |
A |
A |
A |
C |
A |
[0086] Examples 1 to 7 gave all satisfactory results in combustion test, bulkiness of sample
nonwoven fabric, and characteristics (feeling etc.) as cellulosic fibers. Any kind
of fiber (B) did not give difference to the results.
[0087] In Comparative Examples 1, 5, 6, and 10, although the fiber (A) demonstrated effect
and promptly extinguished flame of the surface fabric, small percentages of the fiber
(B) exhibited unsatisfactory formation ability of carbonized films, leading to combustion
of the urethane foams by direct exposure to flame of a burner.
[0088] In Comparative Examples 2, 4, and 8, small percentages of the fiber (A) and fiber
(B) made flame resistance be unsatisfactory, and both of urethane foam and surface
fabric were burned.
[0089] In Comparative Examples 3, 7, and 9, although the fiber (B) formed carbonized films
and urethane foams did not burn, small percentages of the fiber (A) continued combustion
of the surface fabrics.
[0090] In Comparative Example 11, although a high percentage of the fiber (A) and the fiber
(B) demonstrated formation ability of carbonized films and gave satisfactory combustion
test result, absence of the fiber (D) gave inadequate bulkiness.
[0091] In Comparative Examples 4, 5, and 6, smaller percentages of the fiber (A) weakened
ability of extinguishing flame of the sample, and unsatisfactory ability of extinguishing
combustion of the surface fabric was demonstrated.
[0092] In Comparative Examples 5 and 7, larger percentages of the fiber (D) spread flame
of the polyester fiber, and inferior flame resistance was demonstrated.
[0093] Existence of the fiber (D) made bulkiness of sample nonwoven fabrics increase in
both of Examples and Comparative Examples.
[0094] In characteristics (feeling) as a cellulosic fiber, in Comparative Examples 1 to
3, 4, 5, and 6, absence of the fiber (C) did not allow touch as a cellulosic fiber,
and in Comparative Example 9, despite existence of the fiber (C), high ratios of the
fiber (B) demonstrated inferior touch.
(Examples 8 to 12 and Comparative Examples 13 to 20)
[0095] Blended at percentages shown in Table 3 were the fiber (A) obtained in Manufacturing
Example 1; Visil (1.7 dtex, 40 mm of cut length, manufactured by SATERI INTERNATIONAL)
of a silicic acid containing cellulose fiber as the fiber (B); and a polyester fiber
(6.6 dtex, 51 mm of cut length) as the fiber (D), and sample nonwoven fabrics were
manufactured. These samples were used for combustion test. Table 3 shows evaluation
results.
[0096] Although flame resistant fiber composites of Examples 8 to 12 gave satisfactory combustion
result, smaller percentages of the fiber (B) exhibited unsatisfactory formation ability
of carbonized films, leading to combustion of the urethane foams by direct exposure
to flame of a burner in composites of Comparative Examples 13, 14, and 17.
[0097] In Comparative Examples 16, 17, 18, and 19, smaller percentages of the fiber (A)
weakened ability of extinguishing flame of the sample, and unsatisfactory ability
of extinguishing combustion of the surface fabric was demonstrated.
[0098] In composites of Comparative Examples 17 and 20, larger percentages of the fiber
(D) as compared with other fibers spread flame of the polyester fiber, and inferior
flame resistance was demonstrated.
[0099] In addition, in results of sensual evaluation, evaluation of whiteness of sample
nonwoven fabrics gave satisfactory results, and yellowish hue of the sample nonwoven
fabrics was not observed in Examples and Comparative Examples. Although Examples gave
satisfactory results in touch evaluation results, Comparative Examples 13, 14, and
17 gave inferior touch due to shortage of amounts of polyester fiber.
(Examples 13 to 21 and comparative examples 21 to 33)
[0100] Blended at percentages shown in Table 4 were the fiber (A) obtained in Manufacturing
Example 2; Basofil of a melamine fiber (having a distribution of a size of a fiber
of approximately 1 to 3.5 dtex, and distribution of 20 to 200 mm of cut length, manufactured
by Basofil Fibers), Visil as a silicon containing cellulosic fiber (1.7 dtex, 40 mm
of a cut length, manufactured by SATERI INTERNATIONAL), and Technora (1.7 dtex, 38
mm of a cut length, manufactured by Teijin, Ltd.) as a para-aromatic polyamide fiber
as fiber (B), ; a rayon (1.5 dtex, 38 mm of a cut length) as the cellulosic fiber
(C); and a polyester fiber (6.6 dtex, 51 mm of a cut length) as the fiber (D), and
sample nonwoven fabrics were manufactured. These samples were used for combustion
test. Table 5 shows evaluation results.
Table4
Example number |
Amount of addition of antimony trioxide to fiber (A) |
Blending ratio in flame resistant fiber composite (% by weight) |
Fiber (A) |
Fiber (B) |
Fiber (C) |
Fiber (D) |
Melamine fiber |
Silicic acid containing cellulose fiber |
Aromatic polyamide fiber |
13 |
0.5 |
55 |
10 |
0 |
20 |
0 |
15 |
14 |
3 |
35 |
15 |
15 |
0 |
0 |
35 |
15 |
3 |
35 |
25 |
0 |
0 |
15 |
25 |
16 |
3 |
35 |
15 |
0 |
0 |
35 |
15 |
17 |
3 |
45 |
15 |
15 |
0 |
0 |
25 |
18 |
3 |
45 |
25 |
0 |
0 |
15 |
15 |
19 |
3 |
45 |
25 |
0 |
15 |
0 |
15 |
20 |
3 |
45 |
0 |
45 |
0 |
0 |
10 |
21 |
3 |
55 |
15 |
15 |
0 |
0 |
15 |
21 |
3 |
25 |
0 |
25 |
0 |
0 |
50 |
22 |
3 |
100 |
0 |
0 |
0 |
0 |
0 |
23 |
- |
0 |
100 |
0 |
0 |
0 |
0 |
24 |
- |
0 |
0 |
100 |
0 |
0 |
0 |
25 |
- |
0 |
0 |
0 |
0 |
0 |
100 |
26 |
3 |
50 |
50 |
0 |
0 |
0 |
0 |
27 |
3 |
50 |
0 |
0 |
0 |
0 |
50 |
28 |
- |
0 |
50 |
50 |
0 |
0 |
0 |
29 |
- |
0 |
50 |
0 |
0 |
0 |
50 |
30 |
- |
0 |
0 |
50 |
0 |
0 |
50 |
31 |
15 |
50 |
0 |
0 |
0 |
5 |
45 |
32 |
15 |
45 |
0 |
0 |
0 |
10 |
45 |
33 |
15 |
35 |
0 |
0 |
0 |
20 |
45 |
Table5
Example number |
Combustion test result |
Sensuousness evaluation result |
Touch evaluation result |
Urethane combustion |
Perforation of sample nonwoven fabric |
Surface fabric combustion |
Feeling of gloss |
Coloring property |
13 |
A |
A |
A |
A |
A |
A |
14 |
A |
A |
A |
A |
A |
A |
15 |
A |
A |
A |
A |
A |
A |
16 |
A |
A |
A |
A |
A |
A |
17 |
A |
A |
A |
A |
A |
A |
18 |
A |
A |
A |
A |
A |
A |
19 |
A |
A |
A |
A |
A |
A |
20 |
A |
A |
A |
A |
A |
A |
21 |
A |
A |
A |
A |
A |
A |
21 |
C |
C |
C |
A |
A |
A |
22 |
C |
C |
A |
A |
A |
C |
23 |
C |
C |
C |
A |
A |
C |
24 |
A |
A |
C |
A |
C |
C |
25 |
C |
C |
C |
A |
A |
A |
26 |
C |
C |
A |
A |
A |
C |
27 |
C |
C |
A |
A |
A |
A |
28 |
A |
A |
C |
A |
C |
C |
29 |
C |
C |
C |
A |
A |
A |
30 |
A |
A |
C |
A |
A |
A |
31 |
C |
C |
A |
C |
A |
A |
32 |
A |
A |
A |
C |
A |
A |
33 |
A |
A |
A |
C |
A |
A |
[0101] All Examples 13 to 21 gave satisfactory combustion test results, and demonstrated
levels being usable as surface fabrics for upholstered furniture in sensuousness and
touch.
[0102] Since comparative Examples 21, 22, 23, 25, 26, 27, 29, and 31 had inadequate amounts
of components for forming carbonized films, and/or since they had inadequate amounts
of components for maintaining structures in the flame resistant fiber composite in
combustion, they formed perforated holes and cracks in sample nonwoven fabrics during
combustion test, leading to combustion of the urethane foams by direct exposure to
flame of a burner.
[0103] Since Comparative Examples 24, 28, and 30, including a large amount of the fiber
(B), had sufficient amounts of components for maintaining structures in the flame
resistant fiber composite in combustion, neither perforations nor cracks was formed.
However, smaller percentages of the fiber (A) weakened ability of extinguishing flame
of the sample, and demonstrated unsatisfactory ability of extinguishing combustion
of the surface fabric.
[0104] Although Comparative Examples 32 and 33 showed satisfactory combustion test results
and levels with usable touch as a surface fabric of upholstered furniture, and exhibited
poor gloss due to inclusion of a large amount of antimony trioxide in the fiber (A),
resulting in properties inadequate for use as a surface fabric of upholstered furniture.
INDUSTRIAL APPLICABILITY
[0105] Use of the flame resistant fiber composite of the present invention may provide fabrics
having outstanding characteristics of the flame resistant fiber composite of the present
invention, namely, characteristics, such as outstanding flame resistance, sensuousness,
touch, feeling, moisture absorptivity. The fabrics comprise textiles, knittings, nonwoven
fabrics, and strings, and may preferably be used in usage requiring advanced flame
resistance and general fiber characteristics, such as outstanding sensuousness, touch,
moisture absorptivity, feeling, etc. The usage includes furniture, such as chair coverings,
beddings, pillow cases, sheets, bedcovers and mattress coverings, and furthermore
surface fabrics for beddings, blankets, materials for barriers inserted between non-flame
resistance fabrics and urethane foams, clothes, such as fire-resistant work uniforms,
interior designed products, such as curtains and carpets etc.
1. A flame resistant fiber composite obtained by compounding:
20 to 85% by weight of a fiber (A) containing 0.5 to 50 parts by weight of an Sb compound
to 100 parts by weight of a polymer containing halogen atom of not less than 17% by
weight;
5 to 80% by weight of a heat-resistant fiber (B);
0 to 40% by weight of a cellulosic fiber (C); and
0 to 40% by weight of an inflammable fiber (D), such as chemical fiber.
2. The flame resistant fiber composite according to Claim 1 obtained by compounding:
20 to 85% by weight of a fiber (A) containing 6 to 50 parts by weight of an Sb compound
to 100 parts by weight of the polymer containing halogen atom of not less than 17%
by weight;
15 to 80% by weight of the heat-resistant fiber (B) ; and
0 to 40% by weight of the inflammable fiber (D), such as chemical fiber.
3. The flame resistant fiber composite according to Claim 1 obtained by compounding:
20 to 85% by weight of a fiber (A) containing 0.5 to 50 parts by weight of an Sb compound
to 100 parts by weight of a polymer containing halogen atom of not less than 17% by
weight;
5 to 40% by weight of the heat-resistant fiber (B);
5 to 40% by weight of the cellulosic fiber (C); and
5 to 40% by weight of the inflammable fiber (D), such as chemical fiber.
4. The flame resistant fiber composite according to any one of Claims 1 to 3, wherein
the polymer containing halogen atom is a copolymer comprising:
30 to 70% by weight of acrylonitrile;
70 to 30% by weight of a halogen containing vinyl based monomer; and
0 to 10 % by weight of a vinyl monomer copolymerizable therewith.
5. The flame resistant fiber composite according to any one of Claims 1 to 3, wherein
the heat-resistant fiber (B) is selected from silicic acid containing cellulosic fibers,
aramid fibers, and melamine fibers.
6. The flame resistant fiber composite according to Claim 1 or 3, wherein the cellulosic
fiber (C) is a fiber without flame resisting treatment selected from cotton, hemp,
acetate based fibers, and rayon based fibers.
7. The flame resistant fiber composite according to any one of Claims 1 to 3, wherein
the inflammable fiber (D), such as a chemical fiber, comprises at least one kind of
polyester fibers and nylon fibers.
8. The flame resistant fiber composite according to Claim 2 obtained by compounding:
85 to 20 % by weight of a fiber containing 6 to 50 parts by weight of an Sb compound
to 100 parts by weight of a polymer containing chlorine atom of not less than 17%
by weight as the polymer containing halogen atom;
15 to 80% by weight of a silicic acid containing cellulosic fiber as the heat-resistant
fiber (B); and
0 to 40 % by weight of one or more kinds of the inflammable fiber (D), such as chemical
fibers,
the flame resistant fiber composite being compounded so as to give contents of each
fiber of (A) >= (D) or (B) >= (D).
9. The flame resistant fiber composite according to Claim 2, 3, 7, or 8 comprising 5
to 35% by weight of polyester fibers and/or nylon fibers as the inflammable fiber
(D), such as a chemical fiber, in the flame resistant fiber composite.
10. The flame resistant fiber composite according to Claim 2, 4, 5, 7, 8, or 9, wherein
a silicic acid containing cellulosic fiber as the heat-resistant fiber (B) comprises
20 to 50% by weight of silicic acid therein.
11. The flame resistant fiber composite according to Claim 3, 4, 5, 6, or 7 obtained by
compounding:
80 to 20 % by weight of a fiber (A) containing 6 to 50 parts by weight of an Sb compound
to 100 parts by weight of a polymer containing chlorine atom of not less than 17%
by weight, as the polymer containing halogen atom;
5 to 40% by weight of the heat-resistant fiber (B) ;
5 to 40% by weight of the cellulosic fiber (C); and
5 to 40 % by weight of a polyester fiber as the inflammable fiber (D), such as a chemical
fiber.
12. The flame resistant fiber composite according to Claim 1, 4, 5, 6, or 7 comprising:
30 to 70 % by weight of a fiber, containing 0.5 to 5.5 parts by weight of Sb to 100
parts by weight of a polymer containing chlorine atom of not less than 25% by weight
as a polymer containing halogen atom, as the fiber (A);
10 to 50 % by weight of the heat-resistant fiber (B);
5 to 40 % by weight the cellulosic fiber (C); and
0 to 30 % by weight of the inflammable fiber (D), such as a chemical fiber, wherein
contents of the fibers (A) to (D) satisfy relationships of
(1) (A) >= (D) ;
(2) (A) + (D) is 50 to 90% by weight; and
(3) (C) + (D) is 30 to 60 % by weight.
13. The flame resistant fiber composite according to Claim 1, 4, or 12, wherein a chlorine
containing polymer as the polymer containing halogen atom is a copolymer comprising:
40 to 60% by weight of acrylonitrile;
60 to 40 % by weight of a chlorine containing vinyl monomer; and
0 to 10 % by weight of a vinyl monomer copolymerizable therewith.
14. The flame resistant fiber composite according to Claim 1, 7, 12, or 13, wherein the
inflammable fiber (D), such as a chemical fiber, comprises 16 to 100% by weight of
at least one kind of fibers of polyester fibers and nylon fibers.
15. The flame resistant fiber composite according to Claim 1, 7, 12, 13, or 14, wherein
the inflammable fiber (D), such as a chemical fiber, is an inflammable fiber comprising
16 to 100% by weight of a polyester fiber.
16. The flame resistant fiber composite according to Claim 1, 12, 13, 14, or 15, wherein
a fiber containing an Sb compound in a polymer as the polymer containing halogen atom
containing chlorine atom is in an amount of 40 to 70% by weight.
17. The flame resistant fiber composite according to Claim 1, 6, 12, 13, 14, 15, or 16,
wherein the cellulosic fiber (C) is in an amount of 30 to 40% by weight.
18. The flame resistant fiber composite according to Claim 1, 12, 13, 14, 15, 16, or 17,
wherein a content of the Sb compound is 0.5 to 3.5 parts by weight to 100% by weight
of the polymers containing chlorine atom as the polymer containing halogen atom.
19. A fabric manufactured using the flame resistant fiber composite according to Claim
1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, or 18.
20. A nonwoven fabric manufactured using the flame resistant fiber composite according
to Claim 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, or 18.