FIELD OF THE INVENTION
[0001] The present invention relates to a flame resistant union fabric. Specifically, the
present invention relates to a union fabric having high degree of flame resistance
consisting of a compound yarn having a halogen-containing flame resistant fiber including
an antimony compound as a principal component, and a cellulosic fiber.
BACKGROUND ART
[0002] In recent years, demand for guarantee of safety of foods, clothes and housings has
become stronger, and necessity for fire-resistant materials is increasing. In such
a situation, a plurality of methods to give flame resistance to a flammable yarn by
compounding general-purpose flammable fibers and flame resistant fibers having high
degree of flame resistance, while maintaining characteristics of the flammable yarn,
have been proposed. As such a compound fiber, for example, Japanese Patent No. 2593985
specification and Japanese Patent No. 2593986 specification disclose a method of using
antimony compounds as a flame resistant agent to be added to the halogen-containing
flame resistant fibers in compounding of halogen-containing flame resistant fibers
and natural fibers.
[0003] Recently, union fabrics using general-purpose cellulosic fibers as a warp yarn and
a halogen-containing flame resistant fiber including antimony compounds as a weft
yarn are often used for interior design products, such as curtains and chair coverings,
because special features of cellulosic fibers, such as natural feeling, hygroscopic
property, and heat resistance, can be exhibited. Among them, union fabrics using cellulosic
fibers as a warp yarn and halogen-containing flame resistant fibers including antimony
compounds as a weft yarn, such as jacquard, dobby, and satin have special feature
with many cellulosic fibers disposed on a surface side of the fabric.
[0004] However, in these union fabrics, uneven existence of cellulosic fibers and halogen-containing
flame resistant fibers in a fabric makes it very difficult to pass a highest flame
resistant class M1 in NF P 92-503 combustion test in France that requires a very high
degree of flame resistance.
[0005] Only international publication No. 01/32968 pamphlet proposes a method applying such
technique furthermore in which a union fabric using a cellulosic fiber as a warp yarn
and a halogen-containing fiber having an antimony compound and a zinc stannate compound
added therein in combination as a weft yarn has a very high flame resistance passing
Class M1 of NF P 92-503 combustion test.
[0006] However, since zinc stannate compounds have a higher cost than that of antimony compounds,
the fiber has a cost higher than that of conventional fibers as compared with independent
addition of the antimony compounds to the halogen-containing fiber, leading to a problem
of higher cost of the union fabric.
[0007] Accordingly, in a union fabric comprising a halogen-containing fiber by addition
of only antimony compounds and a general-purpose fiber, such as a cellulosic fiber,
development of a union fabric exhibiting high flame resistance and classified in Class
M1 of NF P 92-503 combustion test without combined use of zinc stannate compounds
etc. has been long awaited.
[0008] The present invention aims at providing a fabric having high degree of flame resistance
in case of union fabrics consisting of halogen-containing flame resistant fibers and
cellulosic fibers, and classified in class M1 of NF P 92-503 combustion test.
SUMMARY OF THE INVENTION
[0009] The present inventors performed repeated investigation about union fabrics consisting
of modacrylic flame resistant fibers as halogen-containing flame resistant fibers,
and cellulosic fibers. As a result, it was found out that when a compound yarn using
a modacrylic fiber, compounded with other fibers, including antimony compound as a
principal component shows a certain specific thermal behavior, use of the compound
yarn as a warp yarn or a weft yarn might exhibit high flame resistance in union fabrics,
such as jacquard, dobby, and satin weave.
[0010] That is, the present invention relates to a flame resistant union fabric obtained
by co-weaving: 30% to 70% by weight of a compound yarn (A) obtained by compounding
a halogen-containing flame resistant fiber (a-1) including 25 parts (hereinafter abbreviated
as simply part) to 50 parts of an antimony compound into 100 parts of an acrylic based
copolymer obtained by copolymerizing a monomer mixture comprising 30% to 70% by weight
(hereinafter abbreviated as simply %) acrylonitrile, 30% to 70% of a halogen containing
vinyl based monomer, and 0% to 10% of a vinyl based monomer copolymerizable therewith,
with another fiber (a-2), the compound yarn (A) having less than 5% of elongation
under a condition of a load of 300 mg/metric count of No. 17, and of a temperature
range of 100 degrees C to 500 degrees C; and 70% to 30% by weight of a cellulosic
fiber yarn (B).
[0011] The flame resistant union fabric is preferably a union fabric wherein the cellulosic
fiber (B) is at least one kind selected from a group consisting of cotton, hemp, rayon,
polynosic, cupra, acetate, and triacetate.
BEST MODE FOR CARRYING-OUT THE INVENTION
[0012] The present invention relates a flame resistant union fabric obtained by compounding:
30% to 70% by weight of a compound yarn (A) obtained by compounding a halogen-containing
flame resistant fiber (a-1) including 25 parts to 50 parts of an antimony compound
into 100 parts of an acrylic based copolymer obtained by copolymerizing a monomer
mixture comprising 30% to 70% acrylonitrile, 30% to 70% of a halogen containing vinyl
based monomer, and 0% to 10% of a vinyl based monomer copolymerizable therewith, with
another fiber (a-2), the compound yarn (A) having less than 5% of elongation under
a condition of a load of 300 mg/metric count of No. 17, and of a temperature range
of 100 degrees C to 500 degrees C; and 70% to 30% by weight of a cellulosic fiber
yarn (B).
[0013] In the present invention, a fiber yarn including a halogen-containing flame resistant
fiber (a-1) is a fiber used in order to give flame resistance to a union fabric of
the present invention. The halogen-containing flame resistant fiber (a-1) consists
of a composition including an antimony compound in an acrylic based copolymer obtained
by polymerizing a monomer mixture including 30% to 70% acrylonitrile, 30% to 70% of
a halogen containing vinyl based monomer, and 0% to 10% of a vinyl based monomer copolymerizable
with the acrylonitrile and the halogen containing vinyl based monomer (hereinafter
referred to as copolymerizable vinyl based monomer).
[0014] In the monomer mixture used for obtaining the acrylic based copolymer, a percentage
of the acrylonitrile is not less than 30%, and preferably not less than 40% (lower
limit), and it is not more than 70%, and preferably not more than 60% (upper limit).
[0015] In the monomer mixture, a percentage of the halogen containing vinyl based monomer
is not less than 30%, and preferably not less than 40% (lower limit), and it is not
more than 70%, and preferably not more than 60% (upper limit).
[0016] In the monomer mixture, a percentage of the copolymerizable vinyl based monomer is
preferably not less than 1% (lower limit) , and it is not more than 10%, and preferably
not more than 5% (upper limit).
[0017] Of course, the total percentage of the acrylonitrile, the halogen containing vinyl
based monomer, and the copolymerizable vinyl based monomer is adjusted so as to give
100%.
[0018] In the monomer mixture, a percentage of the acrylonitrile of less than the lower
limit or a percentage exceeding the upper limit of the halogen containing vinyl based
monomer does not allow demonstration of sufficient heat-resistance, and a percentage
exceeding the upper limit of the acrylonitrile unit or a percentage of the halogen
containing vinyl based monomer of less than the lower limit gives inadequate flame
resistance. In the monomer mixture, a percentage exceeding the upper limit of the
copolymerizable vinyl based monomer fails to fully exhibit flame resistance and touch
that are special features of the halogen-containing flame resistant fiber.
[0019] Any halogen containing vinyl based monomers can be used, as long as the halogen containing
vinyl based monomer is a vinyl based monomer including halogen atom, preferably bromine
atom or chlorine atom. As examples of the halogen containing vinyl based monomer,
for example, vinyl chloride, vinylidene chloride, vinyl bromide, etc. may be mentioned.
These may be used independently or two or more kinds may be used in combination.
[0020] As the copolymerizable vinyl based monomer, for example, there may be mentioned:
acrylic acid; acrylic esters, such as ethyl acrylate, and propyl acrylate; methacrylic
acid; methacrylic esters, such as methyl methacrylate, and ethyl methacrylate; and
furthermore, acrylamide, vinyl acetate, vinyl sulfonic acid, vinyl sulfonate (sodium
vinyl sulfonate etc.), styrene sulfonic acid, styrene sulfonate (sodium styrene sulfonate
etc.) These may be used independently or two or more kinds may be used in combination.
[0021] As methods of obtaining the acrylic based copolymer by polymerization of the monomer
mixture including the acrylonitrile, halogen containing monomer, and the monomer copolymerizable
therewith, any methods, such as usual vinyl polymerization methods, for example, a
slurry polymerization method, an emulsion polymerization method, a solution polymerization
method, etc., may be adopted without special limitation.
[0022] As preferable examples of the antimony compound, for example, inorganic antimony
compounds, such as antimony trioxide, antimony pentoxide, antimonic acid, and antimony
oxychloride may be mentioned. These may be used independently or two or more kinds
may be used in combination.
[0023] A content of the antimony compound is not less than 25 parts to 100 parts of the
acrylic based copolymer, and preferably not less than 30 parts (lower limit), and
it is not more than 50 parts (upper limit). A content of the antimony compound of
less than the lower limit disables sufficient guarantee of flame resistance of a compounded
flame resistant union fabric. And on the other hand, an amount of the antimony compound
exceeding the upper limit reduces physical properties, such as strength and elongation,
of the halogen-containing flame resistant fiber, leading to problems, such as nozzle
clogging during manufacturing process.
[0024] As methods of adding the antimony compound, as a flame resistant agent, to the acrylic
based copolymer to obtain a composition (halogen-containing flame resistant fiber),
there may be mentioned: a method of dissolving the acrylic based copolymer in a solvent
that can dissolve the copolymer and then of mixing and dispersing the flame resistant
agent into the obtained solution to manufacture a fiber; and a method of immersing
a fiber obtained from the acrylic based copolymer into an aqueous binder solution
including a flame resistant agent and then squeezing, drying, and heat treating to
impregnate the flame resistant agent using after treatment technique etc. Methods
for obtaining a halogen-containing flame resistant fiber are not limited to them,
and other well-known methods may be used.
[0025] As long as a compound yarn (A) obtained by compounding a halogen-containing flame
resistant fiber (a-1) and another fiber (a-2) is a compound yarn having less than
5% of elongation percentage under conditions of a load of 300 mg/metric count of No.
17 and of a temperature range of 100 degrees C to 500 degrees C, the other fiber (a-2)
compounded with the halogen-containing flame resistant fiber (a-1) is not especially
limited. An elongation percentage is more preferably not more than 3%. Since not less
than 5% of elongation percentage of the compound yarn (A) reduces heat resistance
and flame resistance, leading to formation of a hole in a textile fabric when ignited.
[0026] Here, an elongation percentage of the compound yarn (A) is obtained by measuring
a sample length under a fixed load of 300 mg/metric count of No. 17, when a temperature
is raised from 100 degrees C to 500 degrees C at a rate of 100-degree C/minute using
SSC150 (manufactured by Seiko Instruments Inc.). An elongation percentage is defined
as a ratio of a difference between a sample length at the time of a maximum elongation
at 100 degrees C to 500 degrees C, and an original sample length, with respect to
an original sample length.
[0027] Since a compound yarn (A) having an elongation percentage of less than 5% of thermal
behavior under conditions of a load of 300 mg/metric count of No. 17, and of a temperature
range of 100 degrees C to 500 degrees C may be obtained, cotton, rayon, aramid fibers,
nylon fibers, etc. are preferable as the other fiber (a-2). Since especially natural
touch of the fabric can fully be exhibited, cotton and rayon are preferable.
[0028] A percentage of the halogen-containing flame resistant fiber (a-1) is preferably
60 parts to 95 parts in the compound yarn (A), and more preferably 70 parts to 80
parts. And a percentage of the other fiber (a-2) is preferably 40 parts to 5 parts
in the compound yarn (A), and more preferably 30 parts to 20 parts. The halogen-containing
flame resistant fiber (a-1) and the other fiber (a-2) are compounded so as to be 100
parts in total.
[0029] There is shown a tendency for an amount of the halogen-containing flame resistant
fiber (a-1) of less than 60 parts to reduce a content of the halogen-containing fiber
exhibiting flame resistance in the fabric, resulting in decrease in flame resistance.
There is also shown a tendency for an amount exceeding 95 parts of the halogen-containing
flame resistant fiber (a-1) to melt the compound yarn (A) to easily form a hole in
the fabric during combustion test, also resulting in decrease in flame resistance.
[0030] Compounding methods of the halogen-containing flame resistant fiber (a-1) and the
other fiber (a-2) are not especially limited, and blending, twisting, etc. may be
mentioned.
[0031] The cellulosic fiber yarn (B) can be used without special limitation. As examples,
in view of fully exhibiting natural touch, at least one kind of yarn selected from
a group consisting of cotton, hemp, rayon, polynosic, cupra, acetate, and triacetate
is preferable. In view of many advantages, such as washing resistance, dye affinity,
and low cost, especially cotton is preferable among them.
[0032] A flame resistant union fabric of the present invention is manufactured by co-weaving
of the compound yarn (A) and the cellulosic fiber yarn (B) for giving heat-resistance
and natural touch.
[0033] The flame resistant union fabric of the present invention is obtained by co-weaving
one of the compound yarn (A) and the cellulosic fiber yarn (B) for a warp yarn, and
another for a weft yarn, respectively.
[0034] Union fabric itself is a fabric excellent in design having very characteristic appearance,
and especially in co-weaving of the flame resistant fiber and general non-flame resistant
fibers, some certain weaving methods enable a large amount of disposition on a fabric
surface of non-flame resistant fibers with excellent touch or hygroscopic property,
enabling increase in commercial value of the fabric. However, union fabrics that dispose
much non-flame resistant fibers to a fabric surface thereof have low flame resistance
in general as compared with that of plain fabrics. A union fabric of the present invention
obtained by co-weaving the compound yarn (A) and the cellulosic fiber yarn (B) uses
the compound yarn (A) obtained by compounding the halogen-containing flame resistant
fiber (a-1) and the other fiber (a-2), and thereby while maintaining high degree of
flame resistance of class M1 also in a union fabric, the union fabric allows disposition
of a large amount of cotton (B) in the fabric surface, enabling realization of a fabric
having high design property, excellent touch, and excellent hygroscopic property.
In the union fabric, compounding of not only the halogen-containing flame resistant
fiber but the other fiber (a-2) as the compound yarn (A) may suppress contraction
by heat, promote carbonization, and improve flame resistance. Furthermore, both special
features such as flame resistance of the compound yarn (A), and touch of the cellulosic
fiber yarn (B) will be maximized.
[0035] In the flame resistant union fabric, a percentage of the compound yarn (A) is not
less than 30%, and preferably not less than 40% (lower limit), and not more than 70%,
and preferably not more than 60% (upper limit). On the other hand, in the flame resistant
union fabric a percentage of the cellulosic fiber yarn (B) is not less than 30%, and
preferably not less than 40% (lower limit), and it is not more than 70%, and preferably
not more than 60% (upper limit).
[0036] Of course, a total of the compound yarn (A) and the cellulosic fiber yarn (B) is
adjusted to be 100% by weight.
[0037] A percentage of the compound yarn (A) of less than the lower limit in the flame resistant
union fabric fails to provide sufficient flame resistance, and on the other hand,
a percentage exceeding the upper limit fails to fully exhibit special feature as a
flame resistant fiber of the fiber yarn (B).
[0038] Reasons that a flame resistant fiber union fabric of the present invention represents
high flame resistance of class M1 in NF P 92-503 combustion test are not yet certain,
but for example, following reasons can be conceivable.
(1) Use of compound yarn (A) that cannot easily be elongated under temperatures of
100 degrees C to 500 degrees C during heater-heating of combustion test suppresses
contraction of the fabric by heat, and promotes carbonization at the time of contact
to a flame of a heater to improve flame resistance.
(2) Especially, mixing of fibers having thermal decomposition temperatures higher
than that of the halogen-containing fiber, such as cotton, rayon, and aramid fibers,
suppresses calorific power at the time of contact to a flame of a heater.
EXAMPLE
(Flame resistance examination)
[0039] Evaluation of flame resistance of union fabrics was performed according to French
NF P 92-503 method. The French NF P 92-503 combustion test method will be briefly
described. Examined fabric is held horizontally inclined by 30 degrees, an electric
heater with 500 W is brought close to the fabric, and contact with a burner flame
is carried out for 5 seconds at each timing of 20 seconds, 45 seconds, 75 seconds,
105 seconds, 135 seconds, and 165 seconds after heater heating starts. Flame resistance
is judged by a number of seconds in which a flame remains burning, and a distance
of charring. This examination is a very severe combustion test in which contact with
a burner flame is carried out simultaneously with heating by an electric heater.
[0040] Combustion of a union fabric was carried out in four directions of: warp surface
side, warp reverse side, weft surface side, and weft reverse side. Judgment was performed
according to following NF P 92-507 criteria.
Acceptance criteria
[0041]
M1: All flame-remaining periods in 4 directions are not more than 5 seconds
M2: In examination in four directions, at least one sheet has a flame-remaining period
exceeding 5 seconds, and an average distance of charring of not more than 35 cm
M3: In examination in four directions, at least one sheet has a flame-remaining period
exceeding 5 seconds, and an average distance of charring of not more than 60 cm
(Measurement of elongation percentage)
[0042] Using SSC150 (manufactured by Seiko Instruments Inc.) , a sample length to the original
sample length was measured when a testing temperature was raised from 100 degrees
C to 500 degrees C in a rate of 100-degree C/minute under a fixed load of 300 mg/metric
count of No. 17. An elongation percentage is defined as a ratio of a difference between
a sample length at the time of a maximum elongation at 100 degrees C to 500 degrees
C, and an original sample length to an original sample length.
Manufacturing Example 1
(Manufacture of a compound yarn of a halogen-containing flame resistant fiber and
cotton)
[0043] 52 parts acrylonitrile, 46.8 parts vinylidene chloride, and 1.2 parts sodium styrenesulfonate
were copolymerized to obtain an acrylic based copolymer. The obtained acrylic based
copolymer was dissolved in acetone to obtain a solution with a concentration of 30%.
50 parts antimony trioxide were added to 100 parts of the obtained copolymer to prepare
a spinning solution. The obtained spinning solution was extruded into an aqueous solution
of acetone with a concentration of 38% at 25 degree C using a nozzle having 0.07 mm
of pore size, and 33000 numbers of holes, and then after washing with water the obtained
filaments were dried for 8 minutes at 120 degrees C. Then the obtained filaments were
drawn 3 times at 150 degrees C, and subsequently heat-treated for 30 seconds at 175
degrees C to obtain a halogen-containing flame resistant fiber having a size of a
fiber of 3 dtex. A finishing oil for spinning (manufactured by TAKEMOTO OIL & FAT
CO., LTD.) was added to the obtained halogen-containing flame resistant fiber, textured
to form crimps, and subsequently cut into a length of 38 mm. Subsequently, 80 parts
of the cut halogen-containing flame resistant fiber and 20 parts of cotton were mixed
in a state of raw fiber so as to be a total of 100 parts to manufacture a spun yarn
having a metric count of No. 17. Table 1 shows elongation percentage of obtained compound
yarn.
Manufacturing Example 2
(Manufacture of a compound yarn of a halogen-containing flame resistant fiber and
cotton)
[0044] Except mixing 30 parts of cotton to 70 parts of the halogen-containing flame resistant
fiber, a similar method as in Manufacturing Example 1 was repeated to manufacture
a compound yarn and then a spun yarn having a metric count of No. 17 was obtained.
Table 1 shows elongation percentage of obtained compound yarn.
Manufacturing Example 3
(Manufacture of a compound yarn of the halogen-containing flame resistant fiber and
cotton)
[0045] Except for having mixed 40 parts of cotton to 60 parts of the halogen-containing
flame resistant fiber, a similar method as in Manufacturing Example 1 was repeated
to manufacture a compound yarn and then a spun yarn having a metric count of No. 17
was obtained. Table 1 shows elongation percentage of obtained compound yarn.
Manufacturing Example 4
(Manufacture of a compound yarn of the halogen-containing flame resistant fiber and
rayon)
[0046] Except for having mixed 20 parts of rayon to 80 parts of the halogen-containing flame
resistant fiber, a similar method as in Manufacturing Example 1 was repeated to manufacture
a compound yarn and then a spun yarn having a metric count of No. 17 was obtained.
Table 1 shows elongation percentage of obtained compound yarn.
Manufacturing Example 5
(Manufacture of a compound yarn of halogen-containing flame resistant fiber and rayon)
[0047] Except for having mixed 30 parts of rayon to 70 parts of the halogen-containing flame
resistant fiber, a similar method as in Manufacturing Example 1 was repeated to manufacture
a compound yarn and then a spun yarn having a metric count of No. 17 was obtained.
Table 1 shows elongation percentage of obtained compound yarn.
Manufacturing Example 6
(Manufacture of a compound yarn of halogen-containing flame resistant fiber and rayon)
[0048] Except for having mixed 40 parts of rayon to 60 parts of the halogen-containing flame
resistant fiber, a similar method as in Manufacturing Example 1 was repeated to manufacture
a compound yarn and then a spun yarn having a metric count of No. 17 was obtained.
Table 1 shows elongation percentage of obtained compound yarn.
Comparative Manufacturing Example 1
(Manufacture of a halogen-containing flame resistant fiber)
[0049] A halogen-containing flame resistant fiber was manufactured in a same manner as in
Manufacturing Example 1, and a spun yarn having a metric count of No. 17 was obtained
without mixing cellulosic fiber. Table 1 shows elongation percentage of obtained compound
yarn. Examples 1 to 6
(Manufacture of union fabrics)
[0050] Using a spun yarn of cotton with a metric count of No. 51 (percentage of the warp
yarn 55%) as a warp yarn with a density of 155 units/2.54 cm (1 inch), compound spun
yarns manufactured in the Manufacturing Examples 1 to 6 were woven with a density
of 42 units/2.54 cm (1 inch) (percentage of the weft yarn 45%) as weft yarns into
union fabrics having a 5 harness satin weave. The obtained union fabrics were evaluated
for flame resistance. Table 1 shows results.
Comparative Example 1
(Manufacture of union fabrics)
[0051] Except for using a spun yarn manufactured in the Comparative Manufacturing Example
1 as a weft yarn, union fabrics of 5 harness satin weave were manufactured in the
same manner as in Examples 1 to 6. The obtained union fabric was evaluated for flame
resistance. Table 1 shows results.
Table 1
EXAMPLE Number |
Compound yarn (A) |
Mixture ratio of compound yarn (A) / cellulosic fiber yarn (B) in a union fabric |
Flame resistance |
|
Antimony content in Halogen-containing fiber (a-1) (part) |
Other fiber (a-2) |
Mixture ratio (a-1)/(a -2) |
Elongation percentage (%) |
|
|
1 |
50 |
Cotton |
80/20 |
0 |
45/55 |
M1 |
2 |
50 |
Cotton |
70/30 |
0 |
45/55 |
M1 |
3 |
50 |
Cotton |
60/40 |
0 |
45/55 |
M1 |
4 |
50 |
Rayon |
80/20 |
0 |
45/55 |
M1 |
5 |
50 |
Rayon |
70/30 |
0 |
45/55 |
M1 |
6 |
50 |
Rayon |
60/40 |
0 |
45/55 |
M1 |
Comparative Example |
50 |
- |
100/0 |
35 |
45/55 |
M2 |
[0052] As is clear with reference to Table 1, compound yarns (A) in Manufacturing Examples
1, 2, or 3 using the halogen-containing flame resistant fiber including antimony trioxide
as a flame resistant agent and cotton have 0% of elongation percentage at 500 degrees
C. And combustion test results of union fabrics in Examples 1, 2, or 3 manufactured
using the compound yarns (A) and spun yarn (B) of cotton has class M1, showing high
flame resistance. Also in Examples 4, 5, or 6 using rayon as a cellulosic fiber, combustion
test results have class M1 to show high flame resistance.
[0053] On the other hand, the spun yarn using only a halogen-containing flame resistant
fiber manufactured by the Comparative Manufacturing Example 1, an elongation percentage
at a temperature of 500 degrees C shows 35%. The union fabric in Comparative Example
1 manufactured using this compound yarn and a spun yarn of cotton has flame resistance
inferior to that of union fabrics obtained in Examples 1 to 6, showing class M2.
[0054] As mentioned above, it may be understood that a union fabric consisting of a compound
yarn obtained by compounding a halogen-containing flame resistant fiber including
antimony trioxide and another fiber, and a cellulosic fiber yarn can give a fabric
having high flame resistance classified into class M1.
INDUSTRIAL APPLICABILITY
[0055] Since a flame resistant union fabric of the present invention is a union fabric having
high degree of flame resistance that may pass class M1 of NF P 92-503 combustion test
in France, it can develop high flame resistance also in union fabrics, such as jacquard,
dobby, and satin weave.