JP3192015B2 - Pile fabric - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a flame-retardant pile fabric suitably used for vehicles, furniture chairs, carpets and the like, and more particularly, to a highly flame-retardant pile fabric used for railway vehicles and the like. Pile fabric having the same.

2. Description of the Related Art Conventionally, pile fabrics having high flame retardancy used in railway vehicles and the like have been prepared by using a heat-melting type fiber in a pile portion and a flame-retardant polyester fiber in a base fabric portion, and adding phosphorus element and phosphorus to the base fabric portion. Flame-retardant pile woven or knitted fabric back-coated with a flame retardant containing one or both of halogen elements (JP-A-59-5378)
No. 1) has been proposed.

However, in the above-described flame-retardant pile woven or knitted fabric, since the pile portion is a mere hot-melt type fiber and has no flame retardancy, the weight of the pile portion is increased, the dye concentration is increased, or the like. Further, when functions such as water repellency and antifouling are imparted to the pile portion, the melt drip property is remarkably reduced, and the flame retardancy of the entire pile woven or knitted fabric is impaired. In addition, in recent years, when a pattern is applied to the surface of a pile yarn colored by ordinary yarn dyeing or anti-dyeing, which has been developed as a high-grade pile woven knit, by various printing processes,
Not only the flame retardancy is impaired for the reasons described above, but also the dyes in the flame-retardant polyester fibers dyed in the base fabric migrate to the pile due to the thermal conditions of the color forming / fixing step in the printing process (color). (Crying), the hue of the pile surface was changed, and not only a predetermined hue could not be obtained, but also the frictional fastness of the product was lowered, so that it had a drawback that it could not be put to practical use.

[0004]

SUMMARY OF THE INVENTION A pile fabric having high flame retardancy used for railway vehicles and the like is a. Flame retardancy is significantly impaired by imparting functionality such as the weight of the pile portion, dye concentration, water repellency, etc., or by printing on a colored pile surface. b. Due to the heat treatment in the printing process, the dye in the base cloth bleaches and changes the hue of the pile yarn, making it impractical as a product. It is an object of the present invention to solve the problems of the conventional pile fabric described above and to provide a pile fabric having high quality and high flame retardancy.

[0005]

Means for Solving the Problems As a result of intensive studies to solve the above-mentioned problems, the present inventor has found that a polyester yarn having a flame-retardant property is used for a pile yarn, and a base fabric portion is made of a heat-fusible fiber. (A) and a polyester fiber (B) containing at least a phosphorus element, and a mixing ratio [%] (X) of the fiber (A) and a phosphorus element [pp] contained in the fiber (B).
m] (Y) was found to be able to achieve this object by making a pile fabric that satisfies the following formula, and reached the present invention. 3000 ≦ (Y-100 · X) ≦ 10000 where 10 ≦ X ≦ 70

Hereinafter, the present invention will be described in detail. The pile fabric having high flame retardancy used for railway vehicles and the like in the present invention is specifically one that passes the flammability standard of JR railway vehicle materials (Railway Supervision Bureau Notification No. 81 No. 196.5). Say. That is, the flammability of the sample is evaluated using a flame in which the sample is inclined at 45 ° and alcohol is burned from the center of the lower end, and as in the flammability test (US Federal Standard MVSS302) applied to automotive materials. If the sample is held horizontally, the flame is indirectly fired for 15 seconds with a burner large source smaller than the other end, and if the flame retardancy (4 in / min or less burning speed) is acceptable, the flammability is clearly considered to be the flame retardancy requirement. Differently, the technical level in commercialization is another area. In the latter case,
Even if flame-retarded fibers are not used, they are usually commercialized using ordinary fiber combinations.

In the present invention, it is important to use a polyester fiber having flame retardancy for the pile yarn. If the pile weight is increased, the dye density of the pile yarn is increased, or the colored pile surface is subjected to printing, etc., as in the conventional technology, the meltability of the heat-meltable fiber This is because combustion cannot be prevented even if the base fabric portion and the base fabric portion containing the flame retardant are back-coated. The polyester fiber having flame retardancy in the pile yarn referred to here may be any one containing a known halogen element (such as bromide) or a phosphorus element. Mixing or copolymerization at the polymer stage, or fiber / yarn Any of these may be applied at the stage of dyeing. However, it is more preferable to contain phosphorus as a main component from the viewpoints of smoke generation and harmful gas generation during combustion. Its content is 3000-10000 ppm, preferably 40 ppm.
00-7000 ppm is good. Phosphorus element is 3000pp
If it is less than m, the flame retardancy is undesirably reduced. On the other hand, if it exceeds 10,000 ppm, the spinnability and the intrinsic physical properties of the fiber are reduced, and the durability of the pile yarn is impaired, which is not economically preferable.

Next, it is important that the base fabric portion is a mixture of the original heat-meltable fiber (hereinafter referred to as fiber A) and a polyester fiber containing at least phosphorus element (hereinafter referred to as fiber B). It is most important for the present invention that the mixing ratio [%] (X) and the phosphorus element [ppm] (Y) contained in the fiber (B) satisfy the following expression. 300 ≦ (Y-100 · X) ≦ 10000 where 10 ≦ X ≦ 70

For the base cloth, it is essential to use colored yarn in order to enhance the product quality of the pile cloth. In the pile fabric having high flame retardancy according to the present invention, the flame-retardant polyester fiber used for the base fabric in the prior art (Japanese Patent Application Laid-Open No. 59-53781) is dyed in a medium to dark color by a known method. Has been used. However, in recent years, the need for high-grade multi-color, multi-pattern, etc. has also increased for pile fabrics, such as railway vehicles, which require a high level of flame retardancy, and various types of print processing (coloring, discharge printing, etc.) have been performed on colored pile fabrics. ) And so on. The flame-retardant polyester fiber contains a flame retardant, so that it is easier to dye than ordinary polyester fiber, and conversely, the dye contained in the fiber is easily drawn out to the fiber surface by heat. Has nature. Therefore, especially in the medium-to-dark colored flame-retardant polyester fibers by heat treatment (generally at 160 to 200 ° C.) at the time of printing or imparting functionality (water repellency, oil repellency, deodorization, etc.) Transfer of the dye to the pile yarn (sublimation by heat) occurs.

In order to solve the above-mentioned problems, the present inventor pays attention to the heat-fusible fibers, and contains at least a phosphorus element in order to obtain the flame retardancy of the base fabric and the entire pile fabric. It has been found that it is most effective to use a mixture with a polyester fiber. The so-called heat-fusible fibers are obtained by adding and dispersing various pigments to heat-meltable fibers such as polyester, polyamide polyimide, polyphenylene sulphite, aramid, and polypropylene, and are azo lake-based, insoluble azo-based, and condensed azo-based. , Anthraquinone-based, phthalocyanine-based, dioxazine-based organic pigments, or various inorganic pigments such as iron oxide, chromium oxide, cobalt blue, lead chromate, ultramarine, carbon black, and the like. Any dyes that can be used for coloring or a mixture thereof can be used. Further, it is desirable that the heat-meltable fiber has a similar thermal decomposition behavior to the flame-retardant polyester fiber or a higher thermal decomposition temperature than the flame-retardant polyester fiber.

The above-mentioned method of mixing the fiber A and the fiber B is a known method, such as blending, blending, combusting, and covering at the stage of raw cotton and yarn, or interweaving and knitting at the time of forming the base fabric portion. Any method may be used as long as the base cloth is uniformly colored. Further, the mixing ratio (X)% of the fiber A and the phosphorus element amount (Y) ppm contained in the fiber B are: 3000 ≦ (Y−100 · X) ≦ 10000
It is most important that 10 ≦ X ≦ 70 (%), and the value of (Y−100 · X) is 3
If it is less than 000, the high flame retardancy referred to in the present invention cannot be obtained. If it exceeds 10,000, the flame retardancy is sufficient, but the content of the phosphorus element in the fiber B becomes high, and the yarn-forming properties and yarn properties are remarkably high. Not only will it be reduced, but it will be economically disadvantageous. (Y
−100 · X) is more preferably 5000 to 80.
00 is desirable. The mixing ratio (X)% of the fiber A is 1
If it is smaller than 0, it cannot be said that the base fabric is colored, and the quality of the entire pile fabric is reduced. When the (X)% exceeds 70, the coloring is sufficient, but the flame retardant effect of the fiber B to be mixed is not sufficiently exhibited, or the phosphorus element amount of the fiber B becomes extremely large, and the yarn forming property of the fiber B and the yarn It is not preferable because physical properties decrease. More preferably, the X (%) value is 3
It is desirable that 0 ≦ X ≦ 60.

[0012]

[Action] The combustion behavior of a polymer material is complicated and further differs depending on the combustion conditions and the like, and even if many polymers are combined, theoretical analysis is almost impossible. The present inventor has long been involved in the commercialization of a polyester fiber containing a phosphorus element, and has achieved the present invention based on the experience obtained by experimenting with a number of combinations of materials. In the pile base fabric portion, the heat-fused fiber (A) and the polyester fiber (B) containing a phosphorus element are individually formed and then mixed together, so that the soaking and the flame retarding can be performed in the same polymer. The effect of increasing the decomposition temperature of the polymer required for flame retardancy and the effect of increasing the heat capacity of the polymer, especially in the case of inorganic pigments used for soaking, are demonstrated from the system applied in The general flame-retardant effect of the compound of formula (1), ie, the effect of blocking oxygen by the protective coating of the phosphoric acid layer formed by thermal decomposition, and the formation of carbonized solids and carbonized coating by organic dehydration by polymetaphosphoric acid. It is considered to be due to have been performed efficiently.

[0013]

【Example】

Examples 1 and 2 Comparative Examples 1 Conventional Examples 1 to 3 A spun yarn of 20 s / 2 was prepared by using 2 d × 51 mm of polyester raw cotton 2d × 51 mm (p = 7000 ppm) copolymerized with a phosphorus element as a pile yarn. Was dyed at 130 ° C. for 30 minutes using a highly light-resistant disperse dye. The dye concentrations used were 2% and 5%.・ For one base fabric part, polyester raw cotton (p = 6000, 8000 ppm) copolymerized with phosphorus element 2d × 51 mm
And a spun yarn of 20 s / 2 using 100% each, and a carbon fiber (1.2 wt%) polyester fiber 3
Spun yarn 20 in which d × 51 mm is blended by 30, 50 and 70%
s / 2 and created. The former was dyed and colored in the same manner as the pile yarn, and the latter was used as it was without the dyeing step. A warp-pile double woven fabric is prepared using the above-described pile yarn and the yarn for the base cloth portion, and a predetermined pile length is obtained in a brushing and shearing process by a usual method.
70 g / m ² ). After that, some products were printed using a rotary printing machine by a known method, fixed in dry heat at 180 ° C. for 5 minutes, washed with a jet dyeing machine, dried, brushed and sheared, The pile fabric shown in No. 1 was obtained.

[0014]

[Table 1]

The conventional example 1 is a polyester fiber which does not have flame retardancy in the pile yarn. However, the dye density of the pile yarn is low and the pile weight is small, so that the flame resistance is good. If the pile weight is increased, the dye concentration is increased, or the pile fabric is printed, the flame retardancy is deteriorated. In Example 1, since the pile yarn is a flame-retardant polyester fiber, the flame retardancy is good even when the pile weight and the dye concentration are large. Not only is it good, but there is no contamination of the pile yarn with the hue of the base fabric. However, as in Comparative Example 1, the value (Y-100 · X) of the phosphorus element content (Y) ppm of the fiber (B) in the base cloth portion and the mixing ratio (X)% of the fiber A is as small as 1000 ppm. The flame retardancy is poor.

[0016]

According to the present invention, it is possible to provide a pile fabric having high quality and high flame retardancy in which the hue of the pile yarn does not change even by heat treatment such as a printing process.

──────────────────────────────────────────────────続 き Continued on front page (51) Int.Cl. ⁷ Identification code FI D04B 1/04 D04B 1/04

Claims (1)

(57) [Claims] 1. A pile yarn made of a polyester fiber having flame retardancy, wherein a base fabric portion is mixed with a heat-fusible fiber (A) and a polyester fiber (B) containing at least a phosphorus element. A pile fabric, wherein the mixing ratio [%] (X) of (A) and the phosphorus element [ppm] (Y) contained in the fiber (B) satisfy the following expression. 3000 ≦ (Y-100 · X) ≦ 10000 where 10 ≦ X ≦ 70