JPS5912290B2 - Flame-retardant oil-impregnated pine - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a flame-retardant oil-impregnated mat, and more particularly, to an oil-impregnated mat product having an excellent combination of dust collection and retention properties, flame retardance, and texture.

Conventionally, oil-impregnated mats, in which the pile threads of the mat are coated with an oil agent, have been widely used in homes, offices, stores, buildings, factories, hospitals, etc. in order to prevent dust from entering indoors from outside. .

Although known oil-impregnated mats are satisfactory for the purpose of collecting dust and retaining it without scattering, the oil agent that is applied or impregnated with it is re-flammable;
Dust collection mats placed in areas where many people come and go may pose a fire hazard.

Conventionally, many substances such as phosphates and organic chlorine substances have been known as flame retardants or flame retardants, and attempts have been made to incorporate these flame retardants into oil-impregnated fiber products. Although many flame retardants show considerable effects on non-oil-containing fibers, they show almost no appreciable effect when combined with oil agents for dust control; Even with something like that, the amount of usage is
It has been found that this significantly impairs the feel of the pile portion of the mat or significantly reduces the strength of the pile yarn.

Therefore, an object of the present invention is to provide a dust-controlling oil-impregnated mat that has an excellent combination of dust collection and retention properties, flame retardancy, and texture.

Another object of the present invention is to provide an oil-impregnated mat that can provide sufficient flame retardancy with a relatively small amount of flame retardant used both for the fibers in the pile portion of the mat and for the dust control oil. be.

Still another object of the present invention is that flame retardant treatment and oil impregnation treatment are relatively easy, and even after repeated washing and regeneration treatments, an excellent combination of dust collection and retention properties, flame retardancy, texture, etc. is maintained. The present invention provides an oil-impregnated mat for dust control.

According to the present invention, at least the surface portion of the mat is composed of pile yarns containing cellulose fibers, and the pile yarns contain an alkali metal salt of 2-pyrrolidone-5-carboxylic acid and a substantially non-drying oil agent. The non-drying oil is applied in an amount sufficient to impart dust collection and retention properties to the pile yarn, and the alkali metal salt of 2-pyrrolidone-5-carboxylic acid is -0.1% by weight or more per pile yarn. An oil-impregnated mat is provided, wherein the alkali metal salt of 2-pyrrolidone-5=carboxylic acid is present in an amount of 1% by weight or more based on the oil agent.

The present invention provides that a combination of cellulose fibers and an alkali metal salt of 2-pyrrolidone-5-carboxylic acid exhibits extremely excellent flame retardant properties against flammable dust control oils, and that this flame retardant property is This is based on the knowledge that cellulosic fibers or oil agents for dust control are affected by impregnation treatment with a significantly small amount of alkali metal salt of 2-pyrrolidone-5-carboxylic acid.

First, it is extremely important from the viewpoint of flame retardance that at least the surface portion of the mat used in the present invention is composed of pile yarn containing cellulose fibers.

Fibers whose surface portion of the mat is composed only of fibers other than cellulose fibers, such as polyvinyl alcohol fibers, polyamide fibers, polyester fibers, acrylic fibers, etc., cannot be treated with 2-pyrrolidone-5-carboxylate. By applying the oil-impregnating treatment, the flame spreads over the entire surface (immediately), and no appreciable flame-retardant effect can be obtained.

In contrast, according to the present invention, the mat surface is constructed of pile yarn containing cellulose fibers, and this pile yarn is
When treated with an alkali metal salt of pyrrolidone-5-carboxylic acid and then subjected to oil impregnation treatment, excellent flame retardant properties can be achieved with a lower application amount, which is completely unexpected from flame retardants that are conventionally added to dust control oils. This fact will be clear from the description of the examples below.

The reason for this is unknown, but the alkali metal salt of 2-pyrrolidone-5-carboxylic acid itself is nonflammable, and
It is thought that this is because the alkali metal salt of pyrrolidone-5-carboxylic acid generates a gas that inhibits the combustion of oil and cellulose during thermal decomposition, but the details are unknown.

In the present invention, examples of cellulose fibers constituting the mat include cotton, rayon, kapok fiber, flax, ramie, hemp, Manila hemp, and sisal hemp.

These cellulose fibers can be used alone or in combination of two or more to form pile yarn, or they can be used in combination with synthetic fibers such as polyvinyl alcohol fibers, polyamide fibers, polyester fibers, acrylic fibers, acrylic fibers, wool, etc. It can be used in

When fibers other than cellulose are used as a blended pile yarn or a pile yarn for mixed fibers, at least 30% by weight, preferably 4% by weight of the pile yarn constituting the surface portion of the mat.
It is desirable that at least 0% by weight, particularly preferably at least 50% by weight, be cellulose fibers.

Of course, synthetic fibers can be used without the above-mentioned limitations if the fibers other than cellulose have short piles that are not exposed on the surface of the mat.

The mat used in the present invention generally has a base fabric of polyester fiber, polypropylene fiber, etc., and at least one kind of spun yarn, filament yarn, etc., having a yarn density of 300 to 2000. ? It is produced by tufting with a basis weight of /m, then making it into a pile length of 3 to 30 mm (cut pile or loop pile), and applying latex such as synthetic rubber to the back side to form a backing.

At this time, highly crimped synthetic fiber yarn (Ku 91 series) is tufted together with spun yarn containing cellulose fibers, and when these tufted yarns are cut into pile yarns under tension, a mat surface is created. A mat with unexposed short pile yarns is obtained, which has the property of maintaining excellent dust collection and retention over a long period of time.

Instead of using highly crimped synthetic yarns, these mats use regular synthetic yarns, and after mat production,
It can also be produced by crimping this pile yarn.

In the present invention, among various flame retardants, it is preferable to use an alkali metal salt of 2-pyrrolidone-5-carboxylic acid, which can be applied in a relatively small amount and improves the dust collection and retention properties and texture of the oil-impregnated mat. This is extremely important in order to impart sufficient flame retardancy to the oil-impregnated mat without compromising its strength, cleanability, durability, etc.

In other words, phosphate-based flame retardants, which are conventionally used for flame retardant treatment of dust control products, cannot achieve the desired flame retardancy unless used in large quantities, and they also have a negative impact on the texture, strength, and texture of oil-impregnated mats. There is a tendency for durability etc. to be significantly impaired.

On the other hand, according to the present invention, 2-pyrrolidone-5-
By using an alkali metal salt of carboxylic acid in an oil-impregnated mat in combination with cellulose fibers, flame retardant properties can be imparted at an amount that is an order of magnitude lower than that of the above-mentioned phosphate-based flame retardants. Moreover, it is possible to maintain the texture and other properties of the oil-impregnated mat similar to those of an untreated oil-impregnated mat.

In the present invention, sodium salts are conveniently used as alkali metal salts, but potassium salts can also be used if desired.

The oil may be of any material as long as it is substantially non-drying, and mineral or vegetable-based lubricating oils and synthetic lubricating oils, which have been widely used in this type of dust control products, are particularly suitable. used.

Mineral oils include refrigerating machine oil, spindle oil, machine oil, liquid paraffin oil, electrical insulation oil, etc. Vegetable oils include castor oil, cottonseed oil, etc. Synthetic oils include alkylbenzene oil, diolefin oil, diester oil, etc. oils, alkylnaphthinate oils, etc. are used.

These oils may be used alone or in combination of two or more.

In the present invention, the alkali metal salt of 2-pyrrolidone-5-carboxylic acid is generally at least 0.1% by weight, preferably at least 0.2% by weight, particularly preferably 0.5% by weight, based on the pile system of the mat. Applying in the above amount is important from the viewpoint of flame retardancy.

Also, the alkali metal salt of 2-pyrrolidone-5-carboxylic acid is at least 1% by weight, preferably 2% by weight based on the oil.
As mentioned above, it is important from the viewpoint of flame retardancy that it is particularly preferably used in a proportion of 5% by weight or more.

On the other hand, if 2-pyrrolidone-5-carboxylate is used in too large a quantity, there is no particular advantage in terms of flame retardancy and it is economically disadvantageous, so 2.0% by weight per pile yarn is used.
or less, especially in an amount of 1.0% by weight or less, and in an amount of 20% per oil agent.
It is preferable to use it in an amount of not more than 10% by weight, especially not more than 10% by weight.

In addition to the above-mentioned components, the oil-impregnated mat of the present invention contains additives such as auxiliaries or modifiers that are known per se, such as cationic, nonionic, or amphoteric surfactants, oil-soluble dyes, and fungicides. , an antibacterial agent, a polishing agent, a perfume, etc., can be blended in amounts known per se.

The application of the alkali metal salt of 2-pyrrolidone-5-carboxylic acid and the application of the oil agent may be performed separately or simultaneously, but the former is generally preferred.

The alkali metal salt of 2-pyrrolidone-5-carboxylic acid is
As mentioned above, sufficient flame retardant properties can be obtained with a significantly small amount of application, so it can be applied to the mat in the form of an aqueous solution by means such as spraying or roll coating.

The concentration of the aqueous solution is preferably in the range of 5 to 50% from the viewpoint of workability.

The oil agent can be applied in the form of a liquid 5 by means such as roll coating, or it can be applied in the form of a diluted solution or aqueous emulsion by means such as spraying or dipping.

For example, a self-adsorbing oil emulsion is formed using a cationic activator, an amphoteric activator, or a combination of these and a nonionic activator, and a mat is immersed in this oil emulsion to form the pile yarn. The emulsion particles of the oil agent are adsorbed onto the surface of the mat, followed by dehydration if desired, and then dried to form a mat coated with the oil agent.

The amount of oil applied to the pile yarn is sufficient to give dust collection and retention properties to the pile yarn, and the specific amount varies depending on the type of pile yarn and the structure of the mat, but the amount per pile yarn The amount is from 1 to 30% by weight, especially from 2 to 20% by weight.

According to the present invention, it is possible to obtain an oil-impregnated mat for dust control that has an excellent combination of properties such as dust collection and retention, flame retardancy, and texture, and furthermore, this flame retardant property can be imparted by applying a small amount of flame retardant. Another advantage is that it can be obtained through relatively simple processing.

The invention is illustrated by the following example.

Example 1 Three No. 8 spun yarns made of 85% by weight of cotton fibers and 15% by weight of rayon fibers and one 1680D nylon filament yarn (wool thread) were added to a base fabric made of plain woven polyethylene terephthalate fibers. And, the basis weight is 1o65g/
rn:, then cut under tension (to a pile length of 10 mm), and coated with nitrile loop dashiene rubber latex on the back side in an amount of 4609/m based on solid content, so that the mat surface is made of cellulose fibers. A 20% aqueous solution of sodium 2-pyrrolidone-5-carboxylate was applied to the pile yarn of a mat made of pile yarn in an amount such that the amount of sodium 2-pyrrolidone-5-carboxylate was 1% by weight per pile yarn. Coated.

Next, spindle oil of ≠60 as an oil agent was applied to the mat pile yarn at a concentration of 10% by weight per pile yarn (weight ratio of sodium 2-pyrrolidone-5-carboxylate/oil agent = o, i ), as a product.

This product was subjected to a flame retardant test in accordance with the Tokyo Fire Department's flame retardant test standards.

According to this standard, if the average char length (average of the maximum char length of test specimen b, the same applies hereinafter) after combustion stops is 10 cIrL or less, it passes the test.

The product of this example has an average carbonization length of 3.8c after combustion stops.
It was IrL.

Comparative Examples 1 and 2 For comparison, an untreated mat without applying sodium 2-pyrrolidone-5-carboxylic acid and an oil agent (Comparative Example 1) and a mat with only an oil agent applied in the same amount as Example 1 (Comparative Example 2)
was subjected to the same flame retardant test as above.

The average carbonization length of the mats of these comparative examples was infinite), and they were recognized as failing.

From the above results, it is understood that when the treatment of the present invention is performed, remarkable flame retardancy is imparted despite the oil impregnation treatment.

Next, when 10 panelists were asked to judge the texture of the mat of Example 1 and the mat of Comparative Example 2, 10 panelists answered that there was no difference in the texture of the two mats.
0%, and it was confirmed that the oil-impregnated mat of the present invention had no deterioration in texture despite being subjected to flameproofing treatment.

-Furthermore, three types of mats, Example 1 and Comparative Examples 1 and 2, were tested for dust collection and dust retention.

The dust collection performance was determined by the total number of times the sample mat was walked outdoors.
The weight increase rate was measured by having 00 test subjects walk on the mat, and the degree of staining was visually observed by 10 panelists and determined by the average of the 10 evaluations.

Dust retention was determined by uniformly scattering Kanto loam powder (JI8 8 types) at a rate of 10g/ze on the pile part of the sample mat, leaving it for a day and night, and then stepping on the mat to determine the number of scattered Kanto loam powder. It was made by measuring with a dust counter.

The results are shown in Table 1.

Table 1 Comparative Example 1 Comparative Example 2 Example 1 Dust-catching weight increase rate *1 10.8% 14.3% 15.1% Soil evaluation $2 2 4 4 Dust retention scattering number $3 1350 210 220* 1; The weight increase rate (total) was determined by the following formula: % where a is the weight of the mat before the test and b is the weight of the mat after the test.

*2; The level of dirt is determined by the following 5 levels: Conspicuously dirty.
・・・5 Very dirty・・・・・・・・・・・・・・・
・・・・・・・・・4 Fairly dirty...
・・・・・・・・・・・・3 Not very dirty...
・・・・・・・・・・・・・・・2 Almost the same as before the test ・Rated 1.

*3; Calculated as the number of particles of 5 μ or more in 1 liter of air after 3 to 4 minutes of stepping.

From the above results, it is understood that the oil-impregnated mat of the present invention can maintain excellent dust collection and dust retention properties.

Example 2 Example 1 except that the applied amount of sodium 2-pyrrolidone-5-carboxylate and the weight ratio of sodium 2-pyrrolidone-5-carboxylate/oil agent were as shown in Table 2 below. An oil-impregnated mat was produced in the same manner.

The results obtained are shown in Table 2.

According to the results in Table 2, the amount of sodium 2-pyrrolidone-5-carboxylate applied to the pile was 0.1% by weight or more,
In particular, the weight ratio of sodium 2-pyrrolidone-5-carboxylate/oil agent is 0.01 or more, particularly 0.2% by weight or more, and the weight ratio of sodium 2-pyrrolidone-5-carboxylate/oil agent is 0.01 or more, especially 0.2% by weight or more.
It can be seen that excellent flame retardancy is exhibited by setting the value to 02 or higher.

Table 2 PCA 60 sushiso PCA sorter/average charcoal soda* dollar oil 60 sushiso precipitate chemical length 1 0.05
wt% 5wt% 0.01 cocm20
．． 1 5 0.02 5.230.1
10 0.01 5.64
0.2 10 0.02
4.35 0.2 20 0
．． 01 5.06 0.5 10 0
．． 05 4.0*2-pyrrolidone-5-sodium carboxylic acid Example 3 Oil impregnation was carried out in the same manner as in Example 1 except that the oil shown in Table 3 below was used instead of the +60 spindle oil in Example 1. The mat was manufactured.

The results obtained are shown in Table 3.

Table 3 Type of oil agent Coating amount Average carbonization length PCA soda * Oil agent Liquid paraffin 150-8 1wt% 10wt% 3.8c
m Refrigerating machine oil 1 10 3.7 Cottonseed oil 1 10 4.1 * Comparative example of 2-pyrrolidone-5-sodium carboxylate 3 In Example 1, instead of 2-pyrrolidone-5-sodium carboxylate, the substances shown in Table 4 below were used. An oil-impregnated mat was produced in the same manner as in Example 1 except that a flame retardant was used.

The test results for these oil-impregnated mats are shown in Table 4 below.

Table 4 Types of flame retardant Application amount Flame retardant Texture Chlorinated paraffin (Toyoparax 145) * 1 ■ Confucian Ammonium sulfate based flame retardant $2 4.1 Bore Stiffening and slightly colored *1, ≠60 spindle An oil:chlorinated paraffin weight ratio of 30:70 was applied in an amount of 10% by weight per pile yarn.

Second, a 10% aqueous solution of an ammonium phosphate flame retardant was applied by spraying to each pile yarn so that the amount of the flame retardant was 5% by weight.

Furthermore, as an oil agent, ≠60 spindle oil is added to the pile yarn. 10% by weight, applied by roll coating. Ta.

When chlorinated paraffin was used, no flame retardant effect was observed, and when ammonium phosphate flame retardant was used, flame retardant effect was observed, but the drawbacks were poor texture and discoloration over time. was recognized.

Example 4 A base fabric consisting of a plain woven fabric of polyethylene terephthalate fibers was coated with two 8-number twisted yarns (8S/2) consisting of 85% by weight of cotton and 15% by weight of rayon and 7 of 100% vinylon.
Two twisted yarns (7S/2) with a pile length of 101m and a basis weight of 644. ! Tufted at 9/m and coated with nitrile-butadiene rubber latex on the back side at 41/m on a dry matter basis.
A mat was prepared by applying an amount of 0.09/m'' to form a backing.

A self-emulsifying emulsion of the following composition: cationic-nonionic surfactant, 3 parts naphthenic mineral oil, 966 parts roseoxybromoic acid butyl ester, 1 part oil was applied to the pile threads of this mat so that the oil per fiber was 10% by weight. Impregnated with self-adsorption and dried.

Next, a 10% solution of sodium 2-pyrrolidone-5-carboxylate was applied to the pile portion of this dry mat by roll coating so that the solid content was 0.5% by weight per pile.

When the obtained oil-impregnated mat was subjected to a flame retardant test, the maximum carbonization length was 4.3 crft and it passed.

After using this oil-impregnated mat for two weeks as an office entrance mat, we collected it, washed the used product, performed the treatment described above, and recycled it. This cycle was repeated 10 times. Almost no changes were observed in properties and dust retention.

Furthermore, almost no decrease in the strength or texture of the fiber pile was observed due to the flameproofing treatment.

Claims (1)

[Claims] 1 At least the surface portion of the mat is composed of pile yarns containing cellulose fibers, and the pile yarns are coated with an alkali metal salt of 2-pyrrolidone-5-carboxylic acid and a substantially non-drying oil. The drying oil agent is used in an amount sufficient to impart dust collection and retention properties to the pile system and in accordance with the above 2-
The alkali metal salt of pyrrolidone-5-carboxylic acid is retained in the pile yarn in an amount of 0.1% by weight or more per pile yarn, and the alkali metal salt of 2-pyrrolidone-carboxylic acid is retained in the pile yarn in an amount of 1% by weight or more per the oil agent. An oil-impregnated mat characterized by being present in a ratio of