JPH0380914B2 - - Google Patents

Description

[Detailed description of the invention]

[Technical Field of the Invention] The present invention relates to a fibrous sheet-like structure imparted with flame retardancy. More specifically, the present invention relates to a flame-retardant fiber sheet-like structure used as an interior material. [Prior art and its problems] In recent years, textile products have come to be widely used as interior materials such as automobile interior materials, upholstery, and curtains. Textile products are heat-retaining, flexible, dyed beautifully,
Although it has advantages such as practical durability, it has the disadvantage of being easily flammable. Therefore, it is a natural idea to try to impart flame retardancy to fibers or textile products used for interior purposes, and many techniques have been proposed so far. For example, JP-A-56-85478, JP-A-Sho.
Some of these are described in Japanese Patent Publication No. 56-118973, Japanese Patent Publication No. 60-4306, etc. However, the flame retardant law regulation FMVSS-302 applied to automobile interior materials, curtains,
In order to pass the fire regulations applicable to rugs, it is necessary to apply large amounts of flame retardant compounds to the fibers or fibrous sheet-like structures. There are disadvantages such as problems such as deterioration of hand and decrease in color fastness due to the addition of such a substance. In particular, sheet-like structures made of artificial suede-like fabrics based on non-woven fabrics developed in recent years have a large basis weight and high air content, so they require large amounts of flame-retardant compounds. In order to obtain physical strength and dimensional stability as a material, it is necessary to use a reinforcing material, and there are problems such as hardening of the material and difficulty in making it flame retardant. [Problems to be Solved by the Invention] The purpose of the present invention is to solve the above-mentioned conventional problems, make it possible to impart good flame retardancy with a relatively small amount of flame retardant compound, and reduce the texture and physical properties. An object of the present invention is to provide a flame-retardant sheet-like structure that prevents flame-retardant damage. [Means for Solving the Problems] The present invention achieves the above object, by forming a base fabric on both sides of the fabric.
each side at least 4 times the other side
Fiber aggregates are intertwined and integrated so that the difference in basis weight is more than double, and a flame-retardant compound is added to the fiber aggregate side of the fiber sheet impregnated with polyurethane, which has a lower basis weight. It is characterized by being coated. In this way, the structure of the fiber sheet is such that one fiber aggregate has a larger basis weight than the other fiber aggregate with respect to the base fabric. By applying the flame-retardant compound, it is possible to diffuse the flame-retardant compound substantially throughout the fiber sheet by capillary action. Therefore, good flame retardancy can be imparted even with a relatively small amount of flame retardant compound. The fiber sheet in the present invention is a fiber sheet-like structure typified by a surface-raised artificial suede fabric made of polyurethane-impregnated fibers, and has a high flame retardant property by adding a small amount of flame retardant compound without changing its surface quality. It can be made into a fibrous sheet-like structure that exhibits flame retardancy and has the physical properties and texture required for practical use. The fiber aggregate as used in the present invention is a nonwoven fabric formed by intertwining short fibers produced by needle punching, water punching, or the like. The base fabric is a fabric made of fibers, and may be woven, knitted, or nonwoven. Preferably, the fabric has a basis weight of 70 to 150 g/m ² and is highly flexible with a coarse weave or knitting density. Intertwined and integrated means that the fiber aggregate and the base fabric are brought into close contact with each other by the entanglement of a large number of short fibers by needle punching. Furthermore, the fiber sheet-like structure of the present invention is produced by interlacing the fiber aggregate and the base fabric and then impregnating them with a polyurethane resin. Physical strength and dimensional stability as an interior material can be obtained by intertwining the fiber aggregate and the base fabric, and regarding the factors related to these characteristics, it is important to know where in the fiber aggregate the base fabric is intertwined. It is not significantly affected by However, in order to impart flame retardant compounds and obtain high flame retardancy, the location of the base fabric is very important. That is, it is necessary to have a difference in the basis weight of the fiber aggregates arranged on both sides of the base fabric in a certain relationship. The fiber aggregate that is bonded and integrated on one side of the base fabric has a larger basis weight than the fiber aggregate that is entangled and integrated on the other side of the base fabric. With this structure, if the flame retardant compound is applied to the fiber aggregate side with a small basis weight, the flame retardant compound will diffuse well, and even a small amount of the flame retardant compound will cover almost the entire fiber sheet. It can be distributed as follows. In this case, even if the flame retardant compound is applied from the side of the fiber aggregate with a large basis weight, good diffusion cannot be obtained, and in order to obtain the necessary flame retardance for the fiber sheet, a larger amount must be applied. flame retardant compounds are required. Due to the above effects, the fiber aggregate on the side with a larger basis weight is 4:1 with respect to the fiber aggregate on the side with a smaller basis weight.
It is necessary to have a relationship of at least 4 times or more. Preferably 10:1 or more, more preferably 15 to 20:1
It is to do so. Moreover, it is important that the base fabric and the fiber aggregates on both sides are not joined with an adhesive, but are integrally entangled by the entanglement of the fibers themselves. Examples of the fibers constituting the fiber aggregate include polyethylene terephthalate or a copolymer of this with sodium isophthalate sulfonate, etc.
All polyester fibers such as polyoxyethyl benzoate and polybutylene terephthalate, polyamide fibers such as nylon 6 and nylon 66, and synthetic fibers such as polyacrylic, polyvinyl alcohol, polypropylene, and polyethylene can be used. In order to more conveniently form a fiber sheet-like structure, it is desirable that the fibers constituting the fiber aggregate be ultrafine fibers of 1 denier or less. The surface of such a fibrous sheet-like structure may be brushed, but the thickness of the base fabric depends on the type of structure,
The thickness varies depending on the use, etc., and is usually 0.5 to 2.0 mm, and the thickness of the base fabric as a reinforcing material is preferably one-third or less, preferably one-fifth or less of the thickness of the fibrous sheet-like structure. The intertwined integrated structure of the fiber aggregate and the base fabric of the present invention is impregnated with a polymeric elastomer such as polyurethane, but if necessary, in addition to the polymer, natural rubber,
It may be a combination of SBR, an acrylic resin, a fluorine resin, or a silicone resin, and may also contain a matting agent, pigment, or stabilizer. The flame retardant compound of the present invention is impregnated into the fiber aggregate having a smaller basis weight in the above-mentioned fiber sheet-like structure. As the flame retardant compound, it is preferable to use one selected from the following A, B, C, D, and E, or a mixture of two or more thereof. A Inorganic phosphorus-containing compounds and their derivatives B Antimony oxide C Halogenated aromatic compounds D Halogenated cycloalkanes E Organic phosphorus-containing compounds Examples of the inorganic phosphorus-containing compounds and their derivatives in A include ammonium phosphate, guanidine phosphate, and ammonium polyphosphate. , guanidine polyphosphate,
Examples include guanylurea phosphate.
Examples of antimony oxide B include antimony trioxide, antimony pentoxide, and antimony trichloride. Examples of the halogenated aromatic compound of C include tetrabromobisphenol A and its ethylene oxide adduct, decabromodiphenyl ether, and hexabromobenzene. Examples of the halogenated cycloalkane compound D include hexabromocyclododecane, tetrabromocyclododecane, perchloropentacyclodecane, and the like. In addition, as the organic phosphorus-containing compound of E, tricresyl phosphate, tetrakisphosphonium salt, N
Hydroxymethyl-3-(dimethylphosphono)propionamide, condensate of tetrakis-hydroxymethyl-phosphonium sulfate and urea, oligo(P-vinyl-P-oxo-1,3-dioxa-2-phosphapentylene or Examples include halogenated phosphate esters.A representative example of halogenated phosphate esters is tris-dichloropropyl phosphate.These flame retardants can be used alone or in a mixture of two or more. Preferably, the flame retardant compound is mixed with acrylic resin, vinyl chloride, polyvinyl alcohol, urethane resin, carboxymethyl cellulose, etc., and the flame retardant compound is fixed to the fiber sheet structure. Effect] According to the fiber sheet-like structure of the present invention, high flame retardance can be obtained by adding a relatively small amount of flame retardant compound.Furthermore, due to the entanglement of short fibers, the fiber aggregate and the base fabric as a reinforcing material are Because it is interlaced and integrated, there is no need to use a binder, and there is no hardening of the texture or decrease in tear strength.The flexibility is comparable to that of ordinary clothing, and it has excellent fit. The flame-retardant fiber sheet-like structure according to the present invention can be used for automobile interior materials such as car seats, rugs, upholstery, curtains, wall coverings, etc. that require flame retardancy. Furthermore, it can be preferably used for clothing applications. [Example] Example 1 The island component is 60 parts of polyethylene terephthalate, the sea component is 40 parts of polystyrene, and if the sea component is removed, 16 parts of polyethylene terephthalate is used. A web consisting of staples of 3.5 denier, 51 mm polymer interlayer array fibers, from which ultrafine fibers with a single filament fineness of 0.13 denier are obtained, is needle-punched to form a non-woven fabric (fabric weight, 180 g/m ² ). A polyester taffeta fabric (basis weight, 80 g/m ² ) was placed on top as a base fabric, and a web (20
g/m ² ), the three parts were simultaneously needle punched to intertwine and integrate the web with the polyester taffeta. This integrated sheet-like material was passed through a 12% polyvinyl alcohol glue solution at a temperature of 98°C to shrink the sheet-like material, impregnate it with the glue material, and then dry it. Next, washing was performed with a trichlorethylene solution to remove most of the polystyrene, which is a sea component of the polymeric interlayer array fibers. Next, this sheet-like material was impregnated with a dimethylformamide solution containing 12% polyurethane, wet-coagulated, removed from polyvinyl alcohol, and dried. Next, the surface of the obtained sheet-like material was buffed with sandpaper and dyed to obtain a fibrous sheet-like structure with a thickness of 0.9 mm. A flame retardant compound having the following composition was coated on the back side of this fibrous sheet-like structure, that is, the fibrous web side with a basis weight of 20 g/m ² before the removal of the sea component, by a knife coating method.
After drying for minutes, a flame-retardant fibrous sheet-like structure was produced. Guanidine polyphosphate 40 parts Carboxymethylcellulose 4 parts Water 56 parts Viscosity 6000 (cps) (at 30°C) On the other hand, as Comparative Example 1 of Example 1 described above, when a fibrous sheet-like structure was produced by the same method as Example 1. The position of the polyester taffeta to be inserted into the fiber sheet-like structure is shifted toward the center and the back side of the
Two types of fibrous sheet-like structures were produced in which the amount of web was adjusted to be one-fold smaller than that of the original. A combustion test was conducted to check the flame retardancy of the fiber sheet-like structures produced in Example 1 and Comparative Example 1 in accordance with the FMVSS-302 standard applied to automobile interior materials. The combustion test results are shown in Table 1. The fiber sheet-like structure of Example 1 passed the FMVSS-302 standard with a coating weight of 7% (burning rate: 100%).
mm/min) and showed self-extinguishing at 12% or more. On the other hand, the fiber sheet-like structure in Comparative Example 1 was 12
% adhesion amount does not pass the FMVSS-302 standard,
In order to obtain self-extinguishing properties, a large amount of flame retardant composition of 28% or more was required. The feel of a flame-retardant fibrous sheet-like structure is affected by the amount of flame-retardant composition deposited, and the product of the present invention is flexible and has a good feel with no slimy feeling, whereas the comparative product has a good feel. It was hard and had a slight slimy feel.

[Table] Example 2 The same fibrous sheet-like structure as in Example 1 and Comparative Example 2. Polyester taffeta as a base fabric was not inserted inside the fibrous sheet-like structure, but was thermally bonded to the back side with a low melting point polyamide resin. A fibrous sheet-like structure was fabricated. Flame retardant processing was carried out using the following flame retardant composition in the same manner as in Example 1. Decabromodiphenyl ether 30 parts Antimony trioxide 10 parts Acrylic resin 5 parts Water 55 parts As a result of evaluating flame retardancy according to FMVSS-302 standard,
The high flame retardancy and good texture of the product of the present invention were demonstrated. The results are shown in Table 2.

【table】

【table】

Claims (1)

[Claims] 1. Fiber aggregates are intertwined and integrated on both sides of the base fabric so that one side has a difference in basis weight of at least four times that of the other side, and is impregnated with polyurethane. 1. A flame-retardant sheet-like structure, which is a fiber sheet, and a flame-retardant compound is coated on the side of the fiber aggregate having a smaller basis weight. 2 The flame retardant compound is the following A, B, C, D,
The flame-retardant sheet-like structure according to claim 1, which is selected from the group of compounds E. A Inorganic phosphorus-containing compound and its derivative B Antimony oxide C Halogenated aromatic compound D Halogenated cycloalkane E Organic phosphorus-containing compound