JP4777892B2 - Flame retardant synthetic fiber, flame retardant fiber composite and upholstered furniture product using the same - Google Patents

Description

  The present invention exhibits high flame retardancy that can be suitably used for textiles that require high flame retardancy, such as bedding and furniture, by exhibiting extremely high carbonization and self-extinguishing properties during combustion. The present invention relates to a flame retardant synthetic fiber, a flame retardant fiber composite containing the flame retardant synthetic fiber, and a upholstered furniture product using the same.

  In recent years, demands for ensuring the safety of clothing, food and housing have increased, and the need for flame retardant materials has increased from the viewpoint of flameproofing. Under such circumstances, in order to prevent a fire during sleeping, which causes great human damage at the time of occurrence, there is an increasing need for imparting flame retardancy to materials used for bedding and furniture.

  In products such as bedding and furniture, flammable materials such as cotton, polyester, and urethane foam are often used on the inside and the surface for comfort and design at the time of use. In order to ensure the flame resistance of these products, by using appropriate flame retardant materials in these products, the products must have high flame retardant properties that prevent flames from flammable materials for a long time. is important. In addition, the flame retardant material must not impair the comfort and design of products such as bedding and furniture.

  Various flame retardant synthetic fibers and flame retardants have been studied in the past for the fiber products used in this flame retardant material. The high flame retardancy and comfort required for products such as bedding and furniture There has not yet been a product that fully combines requirements such as design.

  For example, there is a so-called post-processing flame-proofing method that applies a flameproofing agent to cotton cloth, but there are problems such as variations in the amount of flameproofing agent attached, hardening of the cloth due to adhesion, detachment due to washing, safety to the human body, etc. was there.

  In addition, when polyester, which is an inexpensive material, is used, polyester cannot become a carbonizing component, so when forcedly burned, it melts and has holes, and the structure cannot be maintained. The cotton and urethane foam used for furniture and the like were flared, and the performance was quite inadequate.

  In addition, fabrics made of organic heat-resistant fibers such as aramid fibers and novoloid fibers are excellent in flame retardancy, but are extremely expensive.Furthermore, there are problems with workability at the time of opening, hygroscopicity and poor touch, There is also a problem that it is difficult to obtain a design with high design properties due to low dyeability.

Materials that improve the defects of flame retardant fiber materials used in furniture and bedding, have excellent texture, moisture absorption, and tactile sensation required as general characteristics, and have stable flame retardant properties A flame retardant fiber composite (Patent Document 1) is proposed in which a halogen-containing fiber that is highly flame retardant by adding a large amount of a flame retardant and other fibers that are not flame retardant are combined. In addition, it is a highly flame-retardant fiber composite (Patent Document 2) that can be used for work clothes by mixing a small amount of heat-resistant fiber, and it is excellent in texture and moisture absorption and has a high flame resistance. However, the organic heat-resistant fiber is generally a flame-retardant fiber composite that is colored and has insufficient whiteness of the fabric and has a problem in coloring due to dyeing, and has a problem in design of the product. Furthermore, they have also proposed a flame-retardant nonwoven fabric (Patent Document 3) having a bulkiness from essentially flame-retardant fibers and halogen-containing fibers. In these methods, a plurality of fibers are combined. High flame retardancy cannot be obtained unless used, and the manufacturing process of the product becomes complicated. Organic heat-resistant fibers and fibers that are inherently flame retardant are generally expensive and disadvantageous in terms of cost. There was a problem that there was. There are also flame-retardant polyester materials that are flame-retarded with glass components. However, since the amount of glass components is remarkably large, there are problems with high costs and process stability during fiberization, and fiberization has not been achieved. (Patent Document 4)
JP 61-89339 A JP-A-8-218259 WO03 / 023108 Japanese Patent Laid-Open No. 9-278999

  The present invention is a problem that has been difficult to solve with conventional flame-retardant synthetic fibers, i.e., processability, texture, and tactile feel, flame-retardant synthetic fibers that can be used for furniture, bedding, and the like, An object of the present invention is to easily and inexpensively provide a flame retardant composite and a upholstered furniture product using the same.

  As a result of intensive studies to solve the above-mentioned problems, the present inventors have incorporated a glass component and an antimony compound in combination with a synthetic fiber containing a halogen atom. We have found that it is possible to reduce the amount of glass components that negatively affect the texture and feel. Thus, by exhibiting extremely high carbonization and self-extinguishing properties at the time of combustion, it was possible to obtain a flame-retardant synthetic fiber having high flame retardancy that maintains the fiber form after combustion.

 As a result, it is possible to obtain a textile product used for furniture, bedding, etc. that has flame retardancy and self-extinguishing properties that can withstand a long flame without impairing the design of the flame retardant material. The synthetic synthetic fiber was found to be obtained at low cost. In addition, it was found that the problem of processability and price, which was a problem when using a heat resistant fiber alone, can be improved, the flame retardant synthetic fiber of the present invention, a flame retardant composite containing the flame retardant fiber, And we have reached upholstered furniture products using it.

  That is, in the present invention, 10 parts by weight or more of the fiber (A) containing 6 to 50 parts by weight of the total of the glass component and the antimony compound, 100 parts by weight of halogen atoms and 17 parts by weight or more, natural fibers and / or chemicals. A flame-retardant synthetic fiber and a flame-retardant fiber composite composed of 90 parts by weight or less of at least one kind of fiber (B), and a upholstered furniture product using the same, comprising the glass component and the antimony compound agent In the total, the glass component is 5 to 49 parts by weight, the antimony compound is 1 to 45 parts by weight, and the polymer containing 17% by weight or more of the halogen atom is preferably 30 to 70 parts by weight of acrylonitrile, halogen-containing vinyl and / or Or a flame retardant synthesis comprising 70 to 30 parts by weight of a halogen-containing vinylidene monomer and 0 to 10 parts by weight of a vinyl monomer copolymerizable therewith Wei and retardant fiber composite, and to upholstered furniture products using the same. Further, at least one of the natural fibers and / or chemical fibers (B) contains 40 parts by weight or less of a polyester fiber, and the flame retardant fiber composite is a nonwoven fabric, particularly a nonwoven fabric for a flame shielding barrier, The present invention relates to a fiber composite in which a polyester fiber which is a fiber (B) is a low-melting-point binder fiber, and a upholstered furniture product using the same.

 More specifically, the present invention is a flame-retardant synthetic fiber containing a total of 6 to 50 parts by weight of a glass component and an antimony compound with respect to 100 parts by weight of a polymer containing 17% by weight or more of a halogen atom. Preferably, the glass transition temperature of the glass component is 200 to 700 ° C., the glass component is contained in an amount of 5 to 49 parts by weight, the antimony compound is contained in an amount of 1 to 45 parts by weight, and the halogen content of the halogen atom-containing polymer is 20 to 86%, and more preferably the polymer containing 17% by weight or more of the halogen atom is 30 to 70 parts by weight of acrylonitrile, 70 to 30 parts by weight of halogen-containing vinyl and / or halogen-containing vinylidene monomer, and these It is related with a flame-retardant synthetic fiber (A) which consists of 0-10 weight part of vinyl-type monomers copolymerizable with.

 Further, at least one of the natural fibers and / or chemical fibers (B) contains 40 parts by weight or less of a polyester fiber, and the flame retardant fiber composite is a nonwoven fabric, particularly a nonwoven fabric for a flame shielding barrier, The present invention relates to a fiber composite in which a polyester fiber which is a fiber (B) is a low-melting-point binder fiber, and a upholstered furniture product using the same.

 The flame-retardant synthetic fiber of the present invention provides a fiber product having high flame retardancy and self-extinguishing properties that are excellent in design properties such as texture, touch, and visual feel, and processability, and can withstand a long flame. It is possible to do that. In addition, the flame-retardant composite of the present invention and interior fiber products using the same are excellent in design properties such as texture, touch, and visual sense, and processability, and are highly advanced by maintaining the fiber form even for a long flame. It is possible to have flame retardancy.

  The lower limit of the preferable halogen content in the polymer containing 17% or more of the halogen atom of the present invention is 20%, further 26%, the upper limit is 86%, further 73%, especially 48%. When the halogen content is less than 17%, it is difficult to make the fiber flame-retardant, which is not preferable. The upper limit of the halogen content is 86% is the halogen content of the vinylidene bromide homopolymer, and this value is the upper limit of the halogen content. In order to obtain a higher halogen content, it is necessary to increase the number of halogen atoms in the monomer, which is not technically practical.

  Examples of the polymer containing a halogen atom of 17% or more include, for example, a polymer of a monomer containing a halogen atom, and a copolymer of a monomer containing a halogen atom and a monomer not containing a halogen atom. A mixture of a polymer containing a halogen atom and a polymer not containing a halogen atom, a monomer or polymer containing no halogen atom during polymerization, and after polymerization, Examples include, but are not limited to, coalescence.

  Specific examples of such a polymer containing 17% by weight or more of halogen atoms include halogen-containing vinyl-based or vinylidene-based polymers such as vinyl chloride, vinylidene chloride, vinyl bromide, vinylidene bromide, vinyl fluoride, vinylidene fluoride, and the like. Monomer homopolymer or two or more copolymers; acrylonitrile-vinyl chloride, acrylonitrile-vinylidene chloride, acrylonitrile-vinyl bromide, acrylonitrile-vinyl fluoride, acrylonitrile-vinyl chloride-vinylidene chloride, acrylonitrile-vinyl chloride -Copolymers of halogen-containing vinyl or vinylidene monomers such as vinyl bromide, acrylonitrile-vinylidene chloride-vinyl bromide, acrylonitrile-vinylidene chloride-vinylidene fluoride and acrylonitrile; vinyl chloride, vinylidene chloride Copolymers of one or more halogen-containing vinyl-based or vinylidene-based monomers such as vinyl bromide, vinylidene bromide, vinyl fluoride, and vinylidene fluoride with acrylonitrile and vinyl monomers copolymerizable therewith A polymer obtained by adding and polymerizing a halogen-containing compound to an acrylonitrile homopolymer; a halogen-containing polyester; a copolymer of vinyl alcohol and vinyl chloride; a polymer obtained by adding chlorine to polyethylene or polyvinyl chloride, and the like. However, it is not limited to these. Moreover, you may use the said homopolymer and copolymer suitably mixing.

  The polymer containing 17% by weight or more of the halogen atom is 30 to 70 parts by weight of acrylonitrile, 70 to 30 parts by weight of a halogen-containing vinyl monomer and 0 to 10 parts by weight of a vinyl monomer copolymerizable therewith, Preferably, in the case of a polymer composed of 40 to 60 parts by weight of acrylonitrile, 60 to 40 parts by weight of a halogen-containing vinyl monomer and 0 to 10 parts by weight of a vinyl monomer copolymerizable therewith, the resulting fiber Is particularly preferable because it has a texture of acrylic fiber while having desired performance (strength, flame retardancy, dyeability, etc.).

  Examples of the vinyl monomers copolymerizable therewith include acrylic acid, its ester, methacrylic acid, its ester, acrylamide, methacrylamide, vinyl acetate, vinyl sulfonic acid, its salt, methallyl sulfonic acid, its salt Styrene sulfonic acid, a salt thereof, 2-acrylamido-2-methylsulfonic acid, a salt thereof, and the like, and one or more of them are used. In addition, it is preferable that at least one of them is a sulfonic acid group-containing vinyl monomer because dyeability is improved.

  Specific examples of the copolymer containing units from the halogen-containing vinyl monomer and acrylonitrile include, for example, a copolymer comprising 50 parts of vinyl chloride, 49 parts of acrylonitrile and 1 part of sodium styrenesulfonate, 47 parts of vinylidene chloride. And a copolymer comprising 51.5 parts of acrylonitrile and 1.5 parts of styrene sulfonic acid soda, 41 parts of vinylidene chloride, 56 parts of acrylonitrile, 3 parts of 2-acrylamido-2-methylsulfonic acid soda and the like. This can be obtained by known polymerization methods.

The glass component used in the present invention, 200 to 700 ° C. may whatever those having a glass transition temperature, for example, SiO ₂ -PbO-based, SiO ₂ -PbO-ZnO-based,
SiO ₂ —B ₂ O ₃ —Na ₂ O system, SiO ₂ —B ₂ O ₃ —PbO system, SiO ₂ —Al ₂ O ₃ system,
B ₂ O ₃ —PbO system, B ₂ O ₃ —ZnO system, B ₂ O ₃ —Na ₂ O—PbO system,
B ₂ O ₃ —PbO—ZnO system, B ₂ O ₃ —P ₂ O ₅ system, B ₂ O ₃ —Bi ₂ O ₃ —ZnO system,
Examples thereof include P ₂ O ₅ —ZnO, but are not limited thereto. Moreover, there is no problem even if these are used in combination. The amount used is 5 to 49 parts by weight, preferably 7 to 40 parts by weight, more preferably 10 to 30 parts by weight, based on 100 parts by weight of the polymer containing 17% or more of halogen atoms. If the amount is less than 5 parts by weight, it is difficult to obtain the required flame retardancy because the shape retention effect of the carbonized layer is not obtained during combustion, and if it exceeds 49 parts by weight, a sufficient shape retention effect can be obtained, but the manufacturing process at the time of fiberization In this case, thread breakage or the like occurs. Moreover, the glass transition temperature of the said glass component is 200 to 700 degreeC, Preferably it is 250 to 600 degreeC. If it is less than 200 ° C., the glass component melts quickly during combustion, and if it exceeds 700 ° C., the glass component does not melt during combustion, so that neither of the intended carbonization effects can be obtained. Further, the average particle size of the glass component is 3 μm or less, avoiding troubles such as nozzle clogging in the production process of the fiber obtained by adding the glass component to the halogen-containing polymer, improving the strength of the fiber, From the viewpoint of dispersion of the glass component particles in FIG. Further, the glass component can be chemically modified on the particle surface to improve the blocking property.

  Examples of the antimony compounds include, but are not limited to, antimony oxide compounds such as antimony trioxide, antimony tetraoxide, and antimony pentoxide, inorganic antimony compounds such as antimonic acid and salts thereof, and antimony oxychloride. is not. The amount is 1 to 45 parts by weight, preferably 3 to 35 parts by weight, and more preferably 5 to 30 parts by weight with respect to 100 parts by weight of a polymer containing 17% or more of halogen atoms. If the amount is less than 1 part by weight, the self-extinguishing effect is small, so that a sufficiently high flame retardance as intended cannot be obtained. If the amount exceeds 45 parts by weight, the effect is saturated and the cost is increased, which is not preferable. .

The flame retardant synthetic fiber of the present invention may contain other additives such as an antistatic agent, a thermal coloring inhibitor, a light resistance improver, a whiteness improver, a devitrification inhibitor, a colorant, and a flame retardant as necessary. It may be included. For example, flame retardants include halogen compounds such as hexabromobenzene, hexabromocyclododecane, chlorinated paraffin, halogen-containing phosphorus compounds such as tris (2,3-dichloropropyl) phosphate, ammonium polyphosphate, dibutylaminophosphate and the like. Compounds, Mg compounds such as magnesium oxide, magnesium hydroxide, magnesium carbonate, stannic oxide, metastannic acid, stannic oxyhalide, stannous hydroxide, tin tetrachloride, ZnSnO ₃ , ZnSn (OH) Sn compounds such as ₆ , Zn compounds such as zinc oxide and zinc borate, Mo compounds such as molybdenum oxide, titanium compounds such as titanium oxide and barium titanate, N compounds such as melamine sulfate and guanidine sulfamate, Aluminum such as aluminum hydroxide Um compounds, zirconium compounds such as zirconium oxide, stannate magnesium stannate, zirconium, zinc stannate, but such as tin compounds such as zinc hydroxystannate are exemplified but not limited thereto.

  Furthermore, the present invention can provide a bedding such as a mattress, a chair, a sofa, a vehicle seat, and the like, which are upholstered by a flame-retardant fiber composite.

  Examples of the mattress include a pocket coil mattress in which a metal coil is used, a box coil mattress, and a mattress in which an insulator in which styrene or urethane resin is foamed is used. By exhibiting flame retardancy due to the flame retardant fiber composite used in the present invention, it is possible to prevent the spread of fire to the structure inside the mattress. A mattress excellent in texture and touch can be obtained.

  On the other hand, as chairs used indoors, tools, benches, side chairs, armchairs, lounge chairs and sofas, seat units (sectional chairs, separate chairs), rocking chairs, folding chairs, stacking chairs, swivel chairs, Or automobile seats, marine seats, aircraft seats, train seats, etc., used outdoors for vehicle seats, etc., but also in these, the internal fire spreads at the same time as the appearance and feel required for normal furniture It is possible to obtain a upholstered product having a function of preventing the above.

  Also, in mattresses and chairs using low-resilience urethane foam having a pressure dispersion function represented by Tempur World (Tempur World, Inc., Tempur World, Inc.), ordinary styrene or urethane resin is foamed. It is extremely flammable compared to mattresses and chairs using foam materials, but it is an internal structure of mattresses and chairs due to the flame retardant properties exhibited by the flame retardant composite used in the present invention. Fire spread to low-resilience urethane foam can be prevented.

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

  The flame retardant fiber composite of the present invention is a composite of halogen-containing flame retardant synthetic fiber (A), natural fiber and / or chemical fiber (B), and is a fabric such as a woven fabric or a non-woven fabric, a sliver or a web. Fiber aggregates, yarns such as spun yarns, synthetic yarns and twisted yarns, and string-like materials such as braids and braids.

  The composite means that the fibers (A) and (B) are mixed by various methods to obtain a cloth containing the fibers in a predetermined ratio, and each of the mixed cotton, spinning, twisting, weaving and knitting stages. It means combining fiber and yarn.

  The flame retardant fiber composite that can be used in the present invention is suitably used as a nonwoven fabric for a flame shielding barrier. The flame-shielding barrier here means that when the flame-retardant nonwoven fabric is exposed to flame, the flame-retardant nonwoven fabric is carbonized while maintaining the fiber form to shield the flame, and the flame moves to the opposite side. Specifically, by sandwiching the flame-retardant nonwoven fabric of the present invention between a surface fabric such as upholstered furniture such as a mattress, chair, sofa, etc. and urethane foam or stuffed cotton which is an internal structure In the event of a fire, the internal structure can be prevented from igniting flames and the damage can be minimized. Non-woven fabric creation methods such as general thermal bond method, chemical bond method, water jet method, needle punch method, stitch bond method and the like can be used as a method for producing a flame retardant nonwoven fabric. After blending, it is created by opening a card with a card and creating a web and applying the web to a nonwoven fabric manufacturing apparatus. In view of the simplicity of the apparatus, the production by the thermal bond method is common if the needle punch method or the polyester-based low melting point binder fiber is used, but it is not limited to these methods.

  The flame retardant fiber composite of the present invention may contain an antistatic agent, a thermal coloration preventing agent, a light fastness improving agent, a whiteness improving agent, a devitrification preventing agent and the like as necessary.

  The flame retardant fiber composite of the present invention thus obtained has desired flame retardancy and has excellent properties such as texture, touch, hygroscopicity, and design.

When producing upholstered furniture using the flame-retardant fiber composite of the present invention, the flame-retardant fiber composite of the present invention has excellent characteristics, that is, excellent flame retardancy, texture, touch, moisture absorption, design Upholstered furniture products having excellent properties such as properties can be obtained.

The flame-retardant synthetic fiber of the present invention may be a short fiber or a long fiber, and can be appropriately selected in the method of use. For example, it is similar to a fiber to be combined to be processed with other natural fibers and chemical fibers. It is preferable to use short fibers having a length of about 1.7 to 12 dtex and a cut length of about 38 to 128 mm in accordance with other natural fibers and chemical fibers used for textile products.

  The reason why the flame-retardant synthetic fiber of the present invention exhibits highly excellent flame retardancy is considered as follows. When a fiber containing 5 to 49 parts by weight of a glass component and 1 to 45 parts by weight of an antimony compound is burned by another flame source with respect to 100 parts by weight of a thermoplastic resin, the components of the polymer are burned. Oxygen is blocked by the non-combustible gas generated by reacting with the halogen atom and the antimony compound contained therein to suppress combustion (self-extinguishing property), so that it becomes a carbide without burning out or burning. In addition, the glass component only melts during combustion and does not burn out. The molten glass component enters between the carbides generated by the combustion of the polymer and solidifies to form a strong carbonized layer (carbonization effect). As a result, the fiber retains its form in the form of carbides without being disintegrated after combustion, so that the flame is cut off and further fire spread is suppressed, thereby exhibiting highly excellent flame retardancy.

  The natural fiber and / or chemical fiber (B) used in the present invention is for imparting excellent texture, touch, design, product strength, washing resistance and durability to the flame retardant fabric of the present invention. It is a component that improves processability when using a flame-retardant nonwoven fabric for bedding and furniture.

  Specific examples of the natural fibers include plant fibers such as cotton and hemp, animal fibers such as wool, camel hair, goat wool, and silk, and specific examples of chemical fibers include viscose rayon fibers. , Recycled fibers such as cupra fibers, semi-synthetic fibers such as acetate fibers, or synthetic fibers such as nylon fibers, polyester fibers, polyester-based low melting point binder fibers, and acrylic fibers, but are not limited thereto. . These natural fibers and chemical fibers may be used alone with the flame retardant synthetic fiber (A), or two or more types may be used with the flame retardant synthetic fiber (A).

  Here, polyester fiber melts when burned, and the carbonized layer formed by the flame-retardant nonwoven fabric becomes stronger by covering the flame-retardant nonwoven fabric, so that bedding and furniture can be used even if exposed to intense flames for a long time. Can provide flame-shielding barrier performance to prevent flames on cotton and urethane foam used in the fabric, it is easy to obtain bulkiness when processed into non-woven fabric, and halogen-containing flame retardant synthesis in the opening machine (card) It is preferable because the damage of the fiber is eased due to the problem of the strength of the fiber. When a polyester-based low-melting-point binder fiber is used, a simple hot-melt bonding method can be adopted when forming a nonwoven fabric. The polyester-based low-melting-point binder fiber may be a low-melting-point polyester single-type fiber or a parallel-type or core-sheath-type composite fiber made of polyester / low-melting-point polypropylene, low-melting-point polyethylene, or low-melting-point polyester. Generally, the melting point of low-melting polyester is approximately 110 to 200 ° C, the melting point of low-melting polypropylene is approximately 140 to 160 ° C, and the melting point of low-melting polyethylene is approximately 95 to 130 ° C. There is no particular limitation as long as it has the ability. In addition, when a polyester fiber having a low melting point is used, a simple needle punch method can be employed when forming a nonwoven fabric.

  In the present invention, 100 parts by weight of the flame-retardant fabric of the present invention is produced from 10 parts by weight or more of the flame-retardant synthetic fiber (A) and 90 parts by weight or less of the natural fiber and / or chemical fiber (B). The mixing ratio is the water resistance, texture, moisture absorption, touch, design, product strength, washing resistance, durability, as well as the flame resistance required for the final product manufactured from the resulting flame retardant nonwoven fabric. It is determined according to the quality. In general, the flame retardant synthetic fiber (A) 95 to 10 parts by weight, preferably 60 to 20 parts by weight, natural fiber and / or chemical fiber (B) 5 to 90 parts by weight, preferably 80 to 40 parts by weight. The composite is made to be 100 parts by weight. When the hot melt bonding method is selected during the production of the nonwoven fabric, it is preferable that at least 10 parts by weight of polyester-based low-melting-point binder fibers are included as natural fibers and / or chemical fibers (B).

  When the amount of the flame retardant synthetic fiber (A) is less than 10 parts by weight, the formation of a carbonized layer for preventing flames from being applied to cotton and urethane foam used for bedding and furniture when exposed to intense flames for a long time. Insufficient and poor self-extinguishing properties, fire resistance is not sufficient.

  The reason why the flame retardant fiber composite of the present invention exhibits highly excellent flame retardancy is considered as follows. When the flame retardant synthetic fiber (A) is combusted by another flame source, the polymer components are combusted, but the combustion is suppressed by the incombustible gas generated from the contained antimony compound (self-extinguishing property). It becomes a carbide without burning out or burning. In addition, the glass component only melts at the time of combustion, and does not burn out, and enters the carbide layer formed by the combustion of the flame retardant synthetic fiber (A) and natural fiber and / or chemical fiber (B), thereby a strong carbonized layer (Carbonization effect). As a result, since the flame retardant fiber composite retains its form without collapsing, the flame does not spread any further and exhibits a highly excellent flame retardancy.

  The flame retardant fiber composite of the present invention is suitably used as a nonwoven fabric for flame shielding barriers. The flame-shielding barrier here means that when the flame-retardant nonwoven fabric is exposed to flame, the flame-retardant nonwoven fabric is carbonized while maintaining the fiber form to shield the flame, and the flame moves to the opposite side. Specifically, in the event of a fire, the flame-retardant nonwoven fabric of the present invention is sandwiched between a surface fabric such as a mattress or upholstered furniture and an internal structure such as urethane foam or stuffed cotton. This prevents flames from igniting internal structures and minimizes damage. As a method for producing a flame retardant nonwoven fabric, nonwoven fabric creation methods such as a general hot melt bonding method, chemical bond method, water jet method, needle punch method, stitch bond method and the like can be used. After the cotton is blended, it is opened by a card, a web is created, and the web is applied to a nonwoven fabric manufacturing apparatus. From the viewpoint of simplicity of the apparatus, it is preferable to use a needle punch method or a polyester-based low-melting-point binder fiber because the production by the hot melt bonding method is general and the productivity is high, but it is not limited thereto.

  The flame retardant fiber composite of the present invention may contain an antistatic agent, a thermal coloring inhibitor, a light fastness improver, a whiteness improver, a devitrification preventive agent, and the like as necessary. There is no problem with coloring or dyeing with pigments.

  The flame retardant fiber composite of the present invention thus obtained has desired flame retardancy and has excellent properties such as texture, touch, hygroscopicity, and design.

  The flame retardant fiber composite is required to have a high degree of flame retardancy, and has a designable fabric tension that is required to have excellent general fiber characteristics such as texture, moisture absorption, touch, and design. Used for furniture products.

  As a method of using the flame-retardant fiber composite of the present invention for upholstered furniture products, the surface fabric may be used in the form of woven fabric or knit, or the surface fabric and internal structure such as urethane foam or stuffed cotton. It may be sandwiched in the form of woven fabric, knit or non-woven fabric. When used for the surface fabric, the fabric made of the flame retardant fiber composite of the present invention may be used instead of the conventional surface fabric. In addition, when a woven fabric or a knit is sandwiched between the surface fabric and the internal structure, the surface fabric may be sandwiched in the manner of overlapping two sheets, or the internal structure is a woven fabric made of the flame retardant fiber composite of the present invention. Or it may be covered with knit. When sandwiched between the surface fabric and the internal structure as a woven fabric for a flame-shielding barrier, the flame retardant fiber of the present invention must be placed on the entire internal structure, and at least the portion in contact with the surface fabric outside the internal structure. Cover the non-woven fabric made of the composite, and stretch the surface fabric over it.

Hereinafter, the present invention will be described in more detail with reference to examples of the flame-retardant synthetic fiber and the flame-retardant fiber composite, but the present invention is not limited to such examples. In addition, the flame retardance of the fiber in an Example was measured as follows using the fiber alone and the nonwoven fabric or the nonwoven fabric composite.
(Flame resistance evaluation by non-woven fabric)
(Preparation of non-woven fabric for flame retardant evaluation test)
After opening the fiber with a roller card, a nonwoven fabric having a basis weight of 200 g / m ² and a length of 20 cm × width of 20 cm was prepared by a needle punch method.
(Flame retardancy evaluation test method)
Prepare a pearlite plate with a length of 200 mm × width 200 mm × thickness 10 mm with a hole with a diameter of 15 cm, and place a non-woven fabric for flame retardancy evaluation test on it. Four sides were fixed with clips so as not to shrink. With this sample facing the non-woven fabric for flame retardancy evaluation test, the center of the sample and the center of the burner are aligned with a gas stove (PA-10H-2 manufactured by Paloma Kogyo Co., Ltd.) 40 mm from the burner surface. I set it. The fuel gas used was propane with a purity of 99% or more, the flame height was 25 mm, and the flame time was 180 seconds. At this time, the evaluation was carried out with a case where there was no through-hole or no crack in the carbonized layer of the flame retardant evaluation test non-woven fabric or composite test piece, and a case where there was a hole or a crack. .
(Flame resistance evaluation by LOI value)
Take 2g of cotton prepared according to the following production example, divide this into 8 equal parts, make 8 cisterns of about 6cm, stand upright on the holder of the oxygen index measuring instrument, and the minimum oxygen necessary for this sample to keep burning 5cm The concentration was measured and used as the LOI value. The larger the LOI value, the harder to burn and the higher the flame retardancy.
(Measurement method of halogen content in fiber)
The obtained copolymer was subjected to elemental analysis on C element, H element and N element by Yanako CHN coder MT-5 manufactured by Yanagimoto Seisakusho Co., Ltd., and N atom was derived from acrylonitrile, and the polymer was determined from the N atom content. The acrylonitrile component content in it was determined. Further, it was assumed that the total amount of p-styrene sulfonic acid soda was copolymerized, the remainder was regarded as a component derived from a halogen monomer, and the halogen content in the halogen-containing copolymer obtained by calculation was determined.
(Production Example 1)
A resin obtained by dissolving a copolymer (halogen atom ratio: 35%) of 51% acrylonitrile, 48% vinylidene chloride and 1% p-styrenesulfonic acid soda in dimethylformamide so that the resin concentration is 30%. Glass components (P2O5-ZnO system manufactured by Asahi Fiber Glass Co., Ltd., ZP150 glass transition temperature of about 350 ° C.) and antimony trioxide were added to the resin weight of the solution to obtain a spinning dope. The spinning solution containing the glass component and antimony trioxide was extruded into a 50% dimethylformamide aqueous solution using a nozzle with a nozzle hole diameter of 0.10 mm and a hole number of 1000 holes, washed with water, dried at 120 ° C., and then stretched 3 times. Then, a halogen-containing fiber was obtained by further heat treatment at 150 ° C. for 5 minutes and further cutting. The obtained fiber was a fine fiber having a fineness of 5.6 dtex and a cut length of 51 mm.
(Examples 1-3, Comparative Examples 1-2)
In accordance with Production Example 1, a halogen-containing fiber having a glass component and antimony trioxide added in the amounts shown in Table 1 was prepared, and the flame resistance was evaluated using a nonwoven fabric and LOI value. The results are shown in Table 1.

Flame retardancy evaluation test results of Examples 1 to 3 and Comparative Examples 1 to 2 The flame test results of Examples 1 to 3 are good, and the nonwoven fabric for flame retardancy evaluation test is a good carbonized layer after heating with a gas stove , And there was no after-flame, cracks or perforations, and the overall judgment passed. On the other hand, in Comparative Example 1, the amount of antimony trioxide was the same as that in Example 1, but since the glass component was small, a good carbonized layer could not be formed, a hole was formed in the nonwoven fabric, and the overall judgment was rejected. . In Comparative Example 2, the total amount of additives is the same as Example 1, and the LOI value is about the same, but the amount of glass component is small, so that a good carbonized layer cannot be formed, and a hole is formed in the nonwoven fabric, making the overall judgment unsatisfactory. Passed.
(Examples 4-6, Comparative Examples 3-5)
In accordance with the production example, a halogen-containing fiber having a glass component and antimony trioxide added in the amounts shown in Table 2 was prepared, and 80 parts by weight of the present fiber and 20% by weight of polyester fiber (6.6 dtex cut length 51 mm, manufactured by Toyobo Co., Ltd.). The flame retardancy evaluation of the nonwoven fabric mixed with the part was carried out. The results are shown in Table 2.

Flame retardancy evaluation test results of Examples 4 to 6 and Comparative Examples 3 to 5 The flame test results of Examples 4 to 6 are good, and the nonwoven fabric for flame retardancy evaluation test is a good carbonized layer after heating with a gas stove There was no afterflame, cracks, or perforations. On the other hand, in Comparative Example 3, the amount of antimony trioxide was the same as that in Example 4, but a good carbonized layer could not be formed because the glass component was small, and holes were formed in the nonwoven fabric. In Comparative Examples 5 and 6, the total amount of the additive was the same as that in Example 4, but since the amount of the glass component was small, a good carbonized layer could not be formed and holes were formed in the nonwoven fabric.

Furthermore, although an Example is given and this invention is demonstrated in more detail, this invention is not limited only to this Example. In addition, the flame retardance of the fiber in an Example was measured as follows using the nonwoven fabric. This is because the flame retardant nonwoven fabric of the present invention is sandwiched between a surface fabric such as upholstered furniture such as a mattress, a chair, a sofa, etc. and urethane foam or stuffed cotton which is an internal structure, so that bedding in the event of a fire It is a simple evaluation method that is supposed to prevent the ignition of the internal structure of furniture and furniture.
(Flame resistance evaluation by nonwoven fabric composite)
(Preparation of non-woven composite for flame retardant evaluation test)
After the fibers mixed at a predetermined ratio were opened with a card, a nonwoven fabric having a basis weight of 200 g / m ² and a length of 20 cm × width 20 cm was prepared by a needle punch method. The entire surface of the nonwoven fabric was wrapped with a polyester woven fabric (weight per unit area: 120 g / cm ² ) as a surface fabric to obtain a nonwoven fabric composite for flame retardancy evaluation test.
(Flame retardancy evaluation test method using nonwoven fabric composite)
Prepare a pearlite plate with a length of 200mm x width 200mm x thickness 10mm with a hole with a diameter of 15cm, set a non-woven composite for flame resistance evaluation test on it, and flame resistance evaluation test during heating Four sides were fixed with clips so that the nonwoven fabric composite for use did not shrink. With this sample facing the non-woven composite for flame retardancy evaluation test, the center of the sample and the center of the burner are aligned with a gas stove (PA-10H-2) manufactured by Paloma Industry Co., Ltd. at 40 mm from the burner surface. Set. The fuel gas used was propane with a purity of 99% or more, the flame height was 25 mm, and the flame time was 180 seconds. At this time, pass the case where there is no unevenness in the thickness of the carbonized film of the non-woven composite for flame retardancy evaluation test, and there are no holes or cracks. Pass the case where there are no holes or cracks in the carbonized film. In the case where there is a hole or a crack, the evaluation was made with a failure X.
(Production Example 2)
A resin obtained by dissolving a copolymer (halogen atom ratio: 35%) of 51% acrylonitrile, 48% vinylidene chloride and 1% p-styrenesulfonic acid soda in dimethylformamide so that the resin concentration is 30%. Glass components (P2O5-ZnO system manufactured by Asahi Fiber Glass Co., Ltd., ZP150 glass transition temperature of about 350 ° C.) and antimony trioxide were added to the resin weight of the solution to obtain a spinning dope.

The spinning solution containing the glass component and / or antimony trioxide was extruded into a 50% dimethylformamide aqueous solution using a nozzle having a nozzle hole diameter of 0.10 mm and a hole number of 1000 holes, washed with water, dried at 120 ° C., and then 3 After drawing to double, a heat treatment was further performed at 150 ° C. for 5 minutes to obtain a halogen-containing fiber. The obtained fiber was a short fiber having a fineness of 5.6 dtex and a cut length of 51 mm.
(Examples 7-12, Comparative Examples 6-9)
In accordance with Production Example 2, a halogen-containing fiber was prepared by adding a glass component and antimony trioxide in the amounts shown in Table 3, and the resulting halogen-containing fiber, polyester fiber (6.6 dtex, cut length 51 mm), rayon fiber (1. (5 dtex, cut length 38 mm) Nonwoven fabric was prepared at a predetermined ratio, and flame retardancy evaluation was performed. The results are shown in Table 3.

  Examples 7 to 12 had good combustion test results, and the nonwoven fabric composite for flame retardancy evaluation test did not generate cracks or holes after heating with a gas stove, and formed a good carbonized film. On the other hand, in Comparative Example 6, since the glass component was small, a good carbonized film could not be formed, and holes were formed in the nonwoven fabric.

  In Comparative Examples 7 and 8, the total amount of the flame retardant was the same as that in Example 7, but a good carbonized film could not be formed because the glass component was not included, and holes were formed in the nonwoven fabric.

In Comparative Example 9, a good carbonized film was not formed because the amount of halogen-containing fiber was small compared to Examples 8 and 9.

Claims (13)

A flame retardant synthetic fiber containing a total of 20 to 50 parts by weight of a glass component and an antimony compound with respect to 100 parts by weight of a polymer containing 17% by weight or more of a halogen atom ,
The flame-retardant synthetic fiber, wherein the glass component is 10 to 40 parts by weight and the antimony compound is 10 to 35 parts by weight . The halogen content of the halogen atoms of 17 wt% or more containing polymer, flame retardant synthetic fibers of claim 1 Symbol mounting, characterized in that a 20 to 86%. The polymer containing 17% by weight or more of the halogen atom is 30 to 70 parts by weight of acrylonitrile, 70 to 30 parts by weight of halogen-containing vinyl and halogen-containing vinylidene monomer, and vinyl monomer 0 to copolymerizable with these. The flame-retardant synthetic fiber according to claim 2, comprising 10 parts by weight. The flame-retardant synthetic fiber according to claim 1, wherein the glass component has a glass transition temperature of 200 to 700 ° C. The glass component is SiO ₂ —PbO, SiO ₂ —PbO—ZnO, SiO ₂ —B ₂ O ₃ —Na ₂ O, SiO ₂ —B ₂ O ₃ —PbO, SiO ₂ —Al ₂ O _3. , _B 2 _O 3 -PbO _based, B ₂ O 3 -ZnO _{system, B 2 O 3 -Na 2 O} -PbO _-based, B ₂ O 3 _{-PbO-ZnO-based, B 2 O 3 -P 2 O} 5 based, _{B 2 O 3 -Bi 2 O 3} -ZnO _-based, flame-retardant synthetic fiber according to claim 4, wherein the at least one selected from P ₂ O 5 -ZnO system. 10 parts by weight or more of the flame retardant synthetic fiber (A) containing 20 to 50 parts by weight of the total of the glass component and the antimony compound with respect to 100 parts by weight of the polymer containing 17% by weight or more of halogen atoms, natural fiber and / or chemical A flame retardant fiber composite comprising 90 parts by weight or less of at least one kind of fiber (B) ,
The flame-retardant synthetic fiber composite, wherein the glass component is 10 to 40 parts by weight and the antimony compound is 10 to 35 parts by weight . The glass component, the flame retardant fiber composite according to claim 6 Symbol mounting having a glass transition temperature of 200 to 700 ° C.. The polymer containing 17% by weight or more of the halogen atom is 30 to 70 parts by weight of acrylonitrile, 70 to 30 parts by weight of halogen-containing vinyl and / or halogen-containing vinylidene monomer, and a vinyl monomer copolymerizable therewith. The flame-retardant fiber composite according to claim 6, comprising 0 to 10 parts by weight. The flame-retardant fiber composite according to claim 6, wherein at least one kind of the natural fiber and / or chemical fiber (B) contains 40 parts by weight or less of polyester fiber. The flame retardant fiber composite according to claim 9, wherein the polyester fiber as the fiber (B) is a low melting point binder fiber. The flame retardant fiber composite according to claim 6 , wherein the flame retardant fiber composite is a nonwoven fabric. The flame retardant fiber composite according to claim 11 , wherein the nonwoven fabric is a nonwoven fabric for a flame shielding barrier. A furniture product upholstered by the flame-retardant composite according to claim 6, 11 or 12 .