JP7493739B2 - Manufacturing method of interior fabric - Google Patents

Description

The present invention relates to interior fabrics that are flame-retardant, water-repellent, antibacterial, and deodorizing, and that can be attached to indoor curtains, walls, etc.

Conventionally, there has been an aircraft interior material that includes a laminate made of a base layer mainly made of polycarbonate and a coating layer laminated on one side of the base layer, and that is designed so that when the laminate is burned in accordance with a heat release test specified in ASTM E906, the maximum heat release rate measured within 5 minutes from ignition is 65 kW/ ^m2 or less (see, for example, Patent Document 1).

JP 2016-078708 A

The above-mentioned conventional aircraft interior materials are lightweight and flame-retardant while still maintaining strength, but because they have a laminate consisting of a base layer and a coating layer, they lack flexibility and do not have water repellency.

In addition, passengers are on board aircraft, particularly passenger planes, and so interior materials with antibacterial and deodorizing properties are required for hygiene and odor prevention reasons, but there was a problem in that no conventional aircraft interior materials had flame retardant, antibacterial or deodorizing properties.

The present invention has been made in consideration of these problems, and aims to provide an interior fabric that is flexible and also has flame retardant, water repellent, antibacterial, and deodorizing properties.

The present invention has been made to solve at least some of the problems described above, and can be realized as the following application examples. Note that the reference symbols and supplementary explanations in parentheses in this section indicate the correspondence with the embodiments described below in order to aid in understanding the present invention, and do not limit the present invention in any way.

[Application Example 1]
The interior fabric of application example 1 comprises a fabric woven with 27.2 to 50.5% by weight of modacrylic fiber and 72.8 to 49.5% by weight of flame-retardant polyester fiber, and a water-repellent layer obtained by applying a fluorine- based water-repellent agent to the fabric and drying it at 120 to 150°C for 1 to 2 minutes to perform a water-repellent treatment , and the modacrylic fiber is Kanecaron fiber .

In such interior fabrics, the use of modacrylic fibers and polyester fibers makes it possible to provide a fabric with flame retardant properties.
Furthermore, since the fabric made of modacrylic fiber and polyester fiber is treated with a fluorine-based water repellent agent, it can be used as a water repellent interior fabric. In addition, since there is no need to laminate a base layer or a coating layer to obtain flame retardancy and water repellency, flexibility can also be obtained.

[Application Example 2]
The interior fabric of application example 2 is the interior fabric of application example 1, wherein the fabric is interwoven with the flame-retardant polyester fiber having 2.0% owf of an antibacterial agent adsorbed thereon.

In such interior fabrics, antibacterial agents are adsorbed onto the polyester fibers, giving the interior fabric antibacterial and deodorizing properties.

In such interior fabrics, by using flame-retardant polyester fibers, it is possible to ensure flame retardancy even if the content of modacrylic fibers is reduced.
In addition, "a combination of 30% by weight or more of modacrylic fiber and 70% by weight or less of flame-retardant polyester fiber" means that when the modacrylic fiber is 30% by weight, the flame-retardant polyester fiber is 30% by weight, and when the modacrylic fiber is 50% by weight, the flame-retardant polyester fiber is 50% by weight. In other words, when the modacrylic fiber and the flame-retardant polyester fiber together amount to 100% by weight, the modacrylic fiber is combined in a ratio of 30% by weight or more and the flame-retardant polyester fiber is 70% by weight or less.

[Application examples3］
The interior fabric of Application Example 3 comprises a fabric interwoven with 50.5 to 66.0% by weight of modacrylic fiber and 49.5 to 34.0% by weight of non-flame retardant polyester fiber, and a water-repellent layer obtained by applying a fluorine-based water-repellent agent to the fabric and drying the fabric at 120 to 150°C for 1 to 2 minutes to perform a water-repellent treatment, and the modacrylic fiber is Kanecaron fiber.This is an interior fabric with the following aims.
[Application Example 4]
The interior fabric of application example 4 is the interior fabric of application example 3, wherein the fabric is interwoven with the non-flame retardant polyester fiber having 2.0% owf of an antibacterial agent adsorbed thereon..

In such interior fabrics, flame-retardant fabrics can be produced even if non-flame-retardant polyester fibers are used.

FIG. 1 is a graph showing the water repellency and flame retardancy of an interior fabric. FIG. 2 is a diagram showing the burning state of a test specimen during a flame retardancy test. FIG. 11 is a diagram showing the water repellency and flame retardancy of an interior fabric in a second embodiment. FIG. 13 is a diagram showing the water repellency and flame retardancy of interior fabrics in other embodiments. FIG. 13 is a diagram showing the results of an antibacterial test performed on an interior fabric in the third embodiment. FIG. 13 is a diagram showing the results of measuring the amount of the antibacterial agent remaining in the interior fabric after washing in the third and fourth embodiments. FIG. 13 is a diagram showing the results of a flame retardancy test performed on the interior fabric in the third and fourth embodiments.

The following describes an embodiment of the present invention with reference to the drawings. Note that the embodiment of the present invention is not limited to the following embodiment, and various forms may be adopted as long as they fall within the technical scope of the present invention.

[First embodiment]
(Method of manufacturing interior fabric 1)
First, a woven fabric is produced by the following steps (1) to (3).

(1) Interweaving: Fabrics are made by interweaving modacrylic fiber wefts with flame-retardant polyester fiber warps. Modacrylic fiber is an acrylic fiber with a weight ratio of acrylonitrile of less than 85% and more than 35%. It is a synthetic fiber mainly made by copolymerizing acrylonitrile and vinyl chloride.

In this embodiment, 50.5% by weight of Kanecaron (registered trademark) manufactured by Kaneka Corporation is used as the modacrylic fiber, and 49.5% by weight of Super Ecstar (registered trademark) manufactured by Teijin Limited is used as the flame-retardant polyester fiber.

As for the interweaving method, various methods that have been conventionally used may be used, and therefore the explanation of the method is omitted.
As the flame-retardant polyester fiber, in addition to Super Ecstar, Anfla (registered trademark) manufactured by Toray Industries, Inc., Crystal flame-retardant yarn manufactured by Kawabo Textured Co., Ltd., and flame-retardant BR manufactured by Yamakoshi Co., Ltd. may also be used.

(2) Pre-scouring Pre-scouring is a process to remove impurities from the fabric and make it possible to carry out the water repellent treatment described later. In pre-scouring, the fabric is immersed in a scouring solution at room temperature, and the scouring solution is heated to 80-90°C for 5-10 minutes after the start of scouring. Then, the fabric is washed with hot water at 60°C for 1-2 minutes.

The scouring liquid used is a mixture of 20 times the amount of water by weight of fabric, 3% caustic soda by weight of fabric, and 1% neutral detergent by weight of fabric.

(3) Water-repellent treatment In the water-repellent treatment, a fluorine-based water-repellent agent was applied and dried with hot air at 120 to 150° C. for 1 to 2 minutes to obtain the interior fabric 1. In this embodiment, Unidyne (registered trademark) by Daikin Industries, Ltd. was used as the fluorine-based water-repellent agent. In this embodiment, Kanecaron was used as the modacrylic fiber, and therefore the drying temperature was set to 120 to 130° C. to ensure the texture of the interior fabric 1.

Also, if the drying temperature is higher than 150°C, the modacrylic fiber will heat harden, so the drying temperature should be kept below 150°C.

(Performance of interior fabric 1)
The interior fabric 1 has water repellency and flame retardancy, and a performance verification test was carried out to evaluate the performance. The test contents and test results are shown in (1) and (2) below.

(1) Water-repellent performance First, the water-repellent performance of the interior fabric 1 will be described. The water-repellent test was performed by a water-repellent degree test (spray test) specified in JIS L 1092 (waterproof test method for textile products). The specific content of the water-repellent test is shown in the following (a) and (b).
(a) 250 ml of water is sprayed onto a test specimen (interior fabric 1) tilted at 45°.
(b) After removing excess water droplets, the wet state is compared with a control sample to judge. In this case, the performance values in the initial state and after the test specimen (interior fabric 1) was washed five times are shown in the grades specified in JIS L 1092.
(c) Water repellency is considered to be acceptable if it is grade 4 or above (grade 4 or 5).

This water repellency test was carried out on test specimens with a number of compositions, and as shown in Figure 1, the combination of 27.2% to 50.5% Kanecaron fiber and 72.8% to 49.5% flame-retardant polyester for interior fabric 1 achieved grade 4 or higher both initially and after five washes.

(2) Flame Retardant Performance Next, a description will be given of the flame retardant performance of the interior fabric 1. The flame retardant test was performed in accordance with the provisions of the flame retardant performance standard for flame retardant articles set forth by the Japan Fire Retardant Association (based on the law: Article 4-3, Paragraphs 3 to 7 of the Enforcement Regulations of the Fire Service Act).

The flame retardancy test for the interior fabric 1 was conducted using a method known as the 45° coil method. The specific details of the flame retardancy test are shown below in (a) to (e).

(a) Test specimen: Five test specimens (interior fabric 1) with a width of 10 cm and a length such that the mass is 1 (if the length exceeds 20 cm, even if it is less than 1 g, it will be considered as 20 cm) (five specimens for one type of interior fabric 1).

(b) Washing method: Wash in water or dry clean, soak in warm water at 50±2°C for 30 minutes.
(c) Conditioning: 24 hours in a thermostatic dryer at 50±2°C, followed by 2 hours or more in a desiccator containing silica gel, or 1 hour in a thermostatic dryer at 105±2°C, followed by 2 hours or more in a desiccator containing silica gel

(d) Combustion method: The test specimen was held in a state inclined at 45° as shown in FIG. 2, and the flame length of the flame-contacting burner 10 was adjusted to 45 mm, and the test specimen was contacted with the flame.
(e) Evaluation criteria: No ignition after three or more flame contacts

This flame retardant test was carried out on test specimens (interior fabric 1) with multiple compositions, and as a result, as shown in Figure 1, it was confirmed that interior fabric 1 meets the flame retardant performance requirements when it is made up of a combination of 27.2% to 50.5% Kanecaron fiber and 72.8% to 49.5% flame-retardant polyester.

(Features of interior fabric 1)
From the results of the water repellency test and the flame retardancy test, it is found that the interior fabric 1 satisfies the criteria for water repellency and flame retardancy of the water repellency evaluation standard, and has water repellency and flame retardancy.
In addition, since the warp yarns are made of flame-retardant polyester fibers, the interior fabric 1 is easy to weave (has good weaving properties).

[Second embodiment]
Next, an interior fabric 2 using non-flame retardant polyester fiber as the polyester fiber will be described. In the second embodiment, the manufacturing method and test method for the interior fabric 2 are the same as those in the first embodiment, and only the materials used and the test conditions are different. Therefore, only the differences will be described and the same points will be omitted.

(1) Interwoven The interior fabric 2 in the second embodiment uses 54.5% by weight of Kanecaron (registered trademark) manufactured by Kaneka Corporation as the modacrylic fiber for the weft, and 45.5% by weight of Semi-Dulle SR manufactured by Teijin Ltd. as the non-flame retardant polyester fiber. Note that, instead of Semi-Dulle SR, Inter SD manufactured by Yamakoshi Corporation or the like may be used as the non-flame retardant polyester.

(2) Water-repellent performance A water-repellent test similar to that of the first embodiment was carried out on test specimens (interior fabric 2) of a plurality of compositions. As a result, as shown in FIG. 3, the interior fabric 2, which had a combination of 50.5% by weight to 66.0% by weight of Kanecaron fiber and 49.5% by weight to 34.0% by weight of non-flame-retardant polyester, secured grade 4 or higher both initially and after five washes, and it was confirmed that the water-repellent performance was satisfactory.

(3) Flame Retardant Performance A flame retardant test similar to that of the first embodiment was carried out on test specimens (interior fabric 2) having a plurality of compositions. As a result, as shown in FIG. 3, it was confirmed that the interior fabric 2 satisfies the flame retardant performance in a combination of 50.5% by weight to 66.0% by weight of Kanecaron fiber and 49.5% by weight to 34.0% by weight of non-flame retardant polyester.

[Third embodiment]
Next, as a third embodiment, an interior fabric 3 in which the interior fabric 2 has antibacterial and deodorizing properties will be described.

(Method of manufacturing interior fabric 3)
The interior fabric 3 uses the same material as the interior fabric 2 in the first embodiment, that is, a weft of modacrylic fiber and a weft of non-flame retardant polyester fiber.

In addition, in the manufacturing process, (1) the antibacterial agent is adsorbed to the non-flame retardant polyester fiber as a pre-weaving process. In other words, 1% of the total weight of the non-flame retardant polyester fiber fabric is added to a bath to make a dye solution, which is then used for dyeing by high-pressure cheese dyeing under moist heat conditions of 130-135°C. This allows 2.0% owf of the antibacterial agent to be adsorbed to the non-flame retardant polyester fiber.

Then, (1) interweaving, (2) pre-scouring, and (3) water-repellent treatment are performed in the same manner as for the interior fabric 1 in the first embodiment.

The reason for carrying out interweaving, pre-refining and water repellent treatment after the antibacterial agent is adsorbed to the non-flame retardant polyester fiber is that the heat resistance temperature of modacrylic fiber and non-flame retardant polyester fiber is different, so the temperature during dyeing cannot be raised sufficiently after interweaving modacrylic fiber and non-flame retardant polyester fiber. In other words, the antibacterial agent cannot be sufficiently adsorbed to the non-flame retardant polyester fiber after interweaving. Therefore, by raising the dyeing temperature at the yarn dyeing stage (process) before interweaving, the antibacterial agent can be sufficiently adsorbed to the non-flame retardant polyester fiber to ensure the necessary antibacterial properties. The same applies to flame retardant polyester fiber.

(Performance of interior fabric 3)
(1) Antibacterial and deodorizing properties Antibacterial tests were performed using the pour plate culture method specified in JIS L 1092:2015 (bacterial liquid absorption method (quantitative test)). In the bacterial liquid absorption method, a bacterial liquid is inoculated onto both the target antibacterial sample and the control fabric and cultured. After a certain period of time has passed under the same conditions, the number of bacteria in the antibacterial sample and the control fabric are measured and compared. The test bacteria used was Staphylococcus aureus NBRC12732.

The conditions for determining whether the test is successful are as follows:
Inoculum concentration (CFU/mL): 1 x 10 ⁵ to 3 x 10 ⁵
Proliferation value [F]: 1.0 or more Maximum and minimum difference (Log) of three samples in the control sample: 1 or less Maximum and minimum difference (Log) of three samples in the test sample: 2 or less

The JIS antibacterial effect is as follows:
Antibacterial activity value [A] ≧ 2.0

The SEK (Sen-i Evaluation Kino) mark certification criteria are as follows:
Antibacterial and deodorizing treatment: Antibacterial activity value [A] ≧ 2.2
・Antibacterial processing (general use): Antibacterial activity value [A] ≧ Growth value [F]
・Antibacterial processing (special purpose): Antibacterial activity value [A] > Growth value [F]
It is as follows.

The results of the antibacterial test performed on the interior fabric 3 are shown in Fig. 5. As shown in Fig. 5(a), a test bacteria concentration of 1.6 x ¹⁰⁵ was used. The test bacteria solution contained 0.05% surfactant (Tween 80).

As shown in Figure 5(b), a standard cotton cloth was used as the standard cloth, and as shown in Figure 5(c), interior fabric 3 was used as the test sample, which was washed five times using the SEK high-temperature accelerated washing method (using JAFET standard detergent blend).

As shown in Figure 5, the test bacteria liquid concentration (see Figure 5(a)), growth value [F], and maximum and minimum differences of the three specimens in the target sample (see Figure 5(b)), and the maximum and minimum differences of the three specimens in the test sample (see Figure 5(c)) all meet the test success criteria, and the antibacterial activity value [A] (see Figure 5(c)) also meets the JIS antibacterial effect criteria.

In addition, the antibacterial and deodorizing finish, the bacteriostatic finish (general use), and the bacteriostatic finish (special use) all meet the SEK Mark certification standards, demonstrating that sufficient antibacterial and deodorizing properties are achieved.

Furthermore, Figure 6(a) shows the results of measuring the amount of residual antibacterial agent after washing the interior fabric 3. In Figure 6(a), L0, which indicates the number of washes, indicates a state in which no washing was performed, while L5 and L10 indicate states in which the fabric was washed 5 and 10 times, respectively, using the SEK high-temperature accelerated washing method.

As shown in FIG. 6(a), when the interior fabric 3 is not washed (L0 state), the residual amount of antibacterial agent is 0.12 [% owf]. When the fabric is washed 5 times (L5 state) and 10 times (L10 state), the residual amount of antibacterial agent is 0.13 [% owf] and 0.12 [% owf], respectively. It can be seen that even when the fabric is washed 10 times, sufficient antibacterial agent remains.

(Flame retardancy test)
Fig. 7(a) shows the results of a flame retardant test on the interior fabric 3. In Fig. 7(a), the interior fabric 3_1 is a 207 [g/ ^m2 ] fabric made of 48.3% modacrylic and 51.7% non-flame retardant polyester, and the interior fabric 3_2 is a 188 [g/ ^m2 ] fabric made of 43.0% modacrylic and 57.0% non-flame retardant polyester.

As shown in Figure 7 (a), the test measured the flame duration, dust duration, and charred area when heated for one minute and three seconds after arrival. The test results showed that the product met the standards for the Japan Fire Retardant Association's flame retardant (I) label.

(Features of interior fabric 3)
In the interior fabric 3, the molecular structure of the flame-retardant polyester has amorphous parts, and when the temperature is raised, gaps appear in the amorphous parts, into which dyes, flame retardants, antibacterial agents, and other chemicals can permeate.

In the case of flame-retardant polyester, the antibacterial dye solution is heated to a temperature of 130-135°C, which creates gaps in the non-crystalline parts of the flame-retardant polyester, allowing the antibacterial agent to penetrate into those gaps. Therefore, the interior fabric 3, which is woven with the flame-retardant polyester and Kanecaron fiber, can be given antibacterial and deodorizing properties in addition to flame retardancy and water repellency.

[Fourth embodiment]
Next, as a fourth embodiment, an interior fabric 4 in which the interior fabric 2 has antibacterial and deodorizing properties will be described.

(Method of manufacturing interior fabric 4)
The interior fabric 4 uses the same material as the interior fabric 1 in the second embodiment, that is, a modacrylic fiber weft and a flame-retardant polyester fiber weft, and an antibacterial agent is adsorbed to the flame-retardant polyester fiber in the same manner as in the third embodiment. This allows 2.0 [% owf] of the antibacterial agent to be adsorbed to the flame-retardant polyester fiber.
Thereafter, similarly to the interior fabric 2 in the first embodiment, (1) interweaving, (2) pre-scouring, and (3) water-repellent treatment are performed.

(Performance of interior fabric 4)
(Antibacterial and deodorizing)
Fig. 6(b) shows the results of measuring the amount of the antibacterial agent remaining after washing the interior fabric 4. As shown in Fig. 6(b), the amount of the antibacterial agent remaining was 0.01 [% owf] or less in all cases where the interior fabric 4 was not washed (state L0), was washed 5 times (state L5), and was washed 10 times (state L10), and it can be seen that the amount of the antibacterial agent remaining did not change even after the number of washes reached 10.

(Flame retardancy test)
7(b) shows the results of a flame retardant test performed on the interior fabric 4. In FIG. 7(b), the interior fabric 4_1 is a 151 g/m ² fabric made by interweaving 62.9% modacrylic and 37.1% flame retardant polyester.

As shown in Figure 7 (b), the test measured the flame remaining time, dust remaining time, and charred area when heated for one minute and three seconds after arrival. The test results showed that the product met the standards for the Japan Fire Retardant Association's flame retardant (I) label.

(Features of interior fabric 4)
As with the flame-retardant polyester in the third embodiment, when the temperature is raised in the interior fabric 4, gaps appear in the amorphous parts of the molecular structure, and dyes, flame retardants, antibacterial agents, and other chemicals can permeate into the gaps.

However, because the amount of gaps that open in the non-crystalline portion due to temperature rise is larger than that of non-flame retardant polyester, the amount of antibacterial agent that penetrates into the gaps is large. Therefore, the antibacterial and deodorizing properties are greater than those of interior fabric 3, which is woven with non-flame retardant polyester and Kanecaron fiber.

[Other embodiments]
(1) In the above embodiment, the weaving properties are improved by using flame-retardant polyester fiber and non-flame-retardant polyester fiber as warp yarns and modacrylic fiber as weft yarns. However, even if the above is reversed, that is, if flame-retardant polyester fiber and non-flame-retardant polyester fiber are used as weft yarns and modacrylic fiber is used as warp yarns, the water repellency and flame retardancy will be the same.

(2) In the above embodiment, either flame-retardant polyester fiber or non-flame-retardant polyester fiber was interwoven with modacrylic fiber to form interior fabric 1, 2, but three types of fibers, flame-retardant polyester fiber, non-flame-retardant polyester fiber, and modacrylic fiber, may also be interwoven to form interior fabric 5.

The results of the water repellency test and flame retardancy test conducted on the interior fabric 5 in the same manner as in the above embodiment are shown in Figure 4. As shown in Figure 4, it was confirmed that the water repellency and flame retardancy were satisfied even when three types of fibers were interwoven.

(3) In the above embodiment, modacrylic fiber was used for the weft and polyester fiber (flame-retardant polyester fiber and/or non-flame-retardant polyester fiber) was used for the warp, but it may be as shown in (a) to (b) below.

(a) The weft thread is made of polyester fiber and the warp thread is made of modacrylic fiber.
(b) A mixture of modacrylic fiber and polyester fiber (flame-retardant polyester fiber and/or non-flame-retardant polyester fiber) in a specified ratio is used for the weft, and a mixture of modacrylic fiber and polyester fiber (flame-retardant polyester fiber and/or non-flame-retardant polyester fiber) in a specified ratio is also used for the warp.

1, 2, 3, 4, 5... Interior fabric 10... Flame burner

Claims (4)

A method for producing an interior fabric using a fabric interwoven with 27.2 to 50.5% by weight of modacrylic fiber and 72.8 to 49.5% by weight of flame-retardant polyester fiber,
The modacrylic fiber is a Kanekalon fiber,
A water-repellent layer is formed by applying a fluorine-based water-repellent agent to the fabric and then drying the fabric at 120 to 150° C. for 1 to 2 minutes.
A method for producing an interior fabric comprising the steps of: The method for producing an interior fabric according to claim 1,
The method for producing an interior fabric is characterized in that the fabric is woven with the flame-retardant polyester fiber having 2.0% owf of an antibacterial agent adsorbed thereon. A method for producing an interior fabric using a fabric interwoven with 50.5 to 66.0% by weight of modacrylic fiber and 49.5 to 34.0% by weight of non-flame retardant polyester fiber, comprising :
The modacrylic fiber is a Kanekalon fiber,
A water-repellent layer is formed by applying a fluorine-based water-repellent agent to the fabric and then drying the fabric at 120 to 150° C. for 1 to 2 minutes.
A method for producing an interior fabric comprising the steps of: The method for producing an interior fabric according to claim 3,
The method for producing an interior fabric is characterized in that the fabric is woven with the non-flame retardant polyester fiber having 2.0% owf of an antibacterial agent adsorbed thereon.