KR101308982B1 - Quasi-noncombustible double raschel knitted goods - Google Patents

Abstract

PURPOSE: A limited combustible double raschel knitted product has fire retardant properties without reduction in a cushioning property, permeability, and a disperse property of pressure; reduces property damage caused by fire as diffusion velocity of fire is reduced working as a firewall in case of fire; and minimizes damage to human life. CONSTITUTION: A limited combustible double rachel knitted product contains a front layer, a rear layer and a medium layer which is formed between the front layer and the rear layer; the front layer is woven with flame resistant fiber or a reformed flame resistance processed fiber; the medium layer is composed of mono filament of the flam resistant fiber or reformed flame resistance processed fiber; the rear layer is woven with a single rayon fiber which is reformed in flame resistant properties blending flame resistant materials in a threading step and cotton fiber which is composed of a carbon fiber with contents with 55 weight% or greater.

Description

Quasi-noncombustible double raschel knitted goods

The present invention relates to a double-Rassel letter having a flame retardant performance, the front layer, the rear layer and the intermediate layer formed between the front layer and the rear layer is composed of fibers of the flame retardant material having a flame-retardant performance of cushioning, breathability and pressure The present invention relates to a quasi-non-combustible double raschel letter of a multilayer three-dimensional structure that maintains dispersibility.

Conventional seat cover fabric (seat cover fabric) has been mainly used a thick warp knit of one layer, these products to increase the weight (density) of fiber weight per unit area (cushion) to give a cushion (cushion) but this is a problem that the breathability is deteriorated Is present.

If the breathability of the seat cover is reduced, the mold grows in the fabric, which is harmful to the human body, shortens the product life, and gives a comfortable and cool feeling when using it. The function of dispersing evenly is deteriorated.

Double raschel was developed to improve cushioning, breathability, and pressure dispersibility as described above. Double raschel is generally triple layered with a mesh cloth to provide comfort, which is an advantage of mesh materials, and enhanced durability. As a letter (knitted paper) having the characteristics of elastic material, and the mesh cloth has an excellent breathability structure has the advantage of excellent cushioning and comfort.

Double Raschel is a functional fabric mainly used as a raw material for shoe soles, sporting goods, automobile seats, special clothing, etc. due to its multi-dimensional structure, which has excellent breathability and elasticity and excellent elastic recovery compared to general meshes.

Conventional double laselle is generally manufactured in the form of a three-dimensional structure that improves cushioning and breathability by integrally combining the cushioning intermediate layer between the surface layer and the back layer having excellent breathability, which is used for the surface layer, back layer, intermediate layer of the double The fiber material must satisfy the properties such as strength, elongation, elasticity to form a three-dimensional structure with improved cushioning, breathability and pressure dispersion.

Accordingly, in order to impart other functionality to the double-lasel fabric, there are restrictions on the material selection or manufacturing method. For example, in order to impart flame retardancy to the double-lasel fabric, the double-lasel is manufactured by flame retardant yarn or modified flame-retardant yarn or after the manufacture of the double-lasel fabric. Flame retardancy can be imparted through flame retardant methods, but since flame retardant materials satisfying the economics while satisfying the properties of double laselle have not yet been developed, a method of imparting flame retardancy through post-processing is generally used.

Korean Laid-Open Patent Publication No. 2011-0056876 discloses a method for manufacturing an antifouling fabric having improved friction durability through a dipping process, a dehydration process, a drying process, and a heat treatment process for an antifouling fabric including a double raschel fabric. Flame retardant is coated on one side of the fabric to impart flame retardancy.

The anti-fouling fabric of the double laselle can be provided with flame retardancy through flame retardancy as well as water repellency, oil repellency, and friction durability. However, since the flame retardant is coated on one side of the fabric, the breathability, which is an advantage of the double laselle, is coated with friction. The flame retardant is easy to break away has the disadvantage of low flame retardant durability.

In addition, Korean Laid-Open Patent Publication No. 2012-0012288 discloses an invention related to a synthetic fiber carpet consisting of a fabric layer, a dimensional stability layer, a cushion layer, the fabric layer is a double-lasel fabric made of polyester fibers, The dimensionally stable layer is a glass fiber fabric, the cushion layer is composed of a foam layer formed by foaming non-flammable polyvinyl chloride.

According to the present invention, the surface of the fabric layer is composed of a double-lasel fabric to obtain a soft touch and cushioning, and the cushion layer is made of a non-combustible material to provide a fire protection function, and the dimensionally stable layer prevents the cushion layer from changing outside temperature. Make sure you maintain a consistent shape.

However, when the carpet containing glass fiber is in direct contact with the human body, it is detrimental to the health and also contains a foam layer. Therefore, it can only be used for limited applications such as carpet, and in case of fire, the foam layer shrinks and the appearance is greatly reduced. There is a problem that can not be performed.

In order to impart flame retardancy to the double laselle fabric as described above, a method of applying a flame retardant material or a flame retardant material has been applied until now, but this has a problem in that the field of use of the flame retardant double laselle is limited. In the meantime, the development of a double raschel showing satisfactory flame retardant performance is required.

The problem to be solved by the present invention is to provide a semi-combustible double-lasel that does not deteriorate even when exposed to a flame without deteriorating the cushioning property, breathability and pressure dispersibility characteristics of the double-lasel while producing a double-lasel from the flame retardant fibers will be.

In order to solve the above problems, the present invention includes a front layer, a rear layer and an intermediate layer formed between the front layer and the rear layer, the front layer is woven by flame retardant yarn or modified flame retardant construction, the intermediate layer is flame retardant yarn Or a monofilament of modified flame retardant fabrication, wherein the back layer is a semi-non-flammable double raschel letter woven from spun yarn composed of rayon short fibers modified by flame retardancy by mixing flame retardants in a spinning step and carbon fibers having a carbon content of 55% by weight or more. To provide.

In this case, the flame retardant yarn of the front layer and the intermediate layer is at least one selected from the group consisting of polytetrafluoroethylene fiber, aramid fiber, polyimide fiber, polyvinyl chloride fiber, polycral fiber, modacryl fiber and novoroid fiber, The modified flame retardant fabrication of the front layer and the intermediate layer is prepared by incorporating and spinning a flame retardant to at least one polymer selected from the group consisting of polypropylene, polyethylene, polyester, polyethylene terephthalate, polybutylene terephthalate, polyamide It is preferable.

In addition, the yarn of the back layer is 1 to 5 denier modified by flame retardancy in the spinning step using a flame retardant, 5 to 95% by weight of rayon short fibers and 1 to 7 denier of fiber length 22 ~ 51㎜, fiber length 38 ~ 76 It is preferably made of 5 to 95% by weight of carbon fibers of 1 mm, selected from the group consisting of 1 to 7 days, 100 to 22 parts by weight of para-aramid short fibers, teflon short fibers and short silica fibers in 100 parts by weight of the yarn. It is more preferable that at least any one of 10 to 70 parts by weight is added.

In addition, the carbon fiber is produced by heating the precursor material of the carbon fiber to 400 ℃ at a rate of 140 ~ 160 ℃ / hour in the air to perform a stabilization process, and then carbonized or carbonized process and graphitization process in an oxygen-free atmosphere It is preferable that the precursor raw material is at least one selected from the group consisting of cellulose, acrylic fiber, vinylon, pitch, aromatic polyamide, phenol and perfuryl resin.

In addition, the flame retardant is preferably at least one selected from the group consisting of phosphoric acid, triphenyl phosphate, tricresyl phosphate and trichloroethyl phosphate.

The quasi-non-combustible double-lasel letter according to the present invention is manufactured by using a flame-retardant fiber, so that the cushion, breathability and pressure dispersibility, which are characteristics of the double-lasel, can be provided without deterioration, and the shrinkage rate after combustion is less than 5%. It can act as a firewall in case of fire, reducing the spread rate of the flame, thereby reducing property damage caused by fire and minimizing human injury.

In addition, the double-Rassel letter of the present invention is made of flame retardant and semi-flammable fibers rather than post-flame retardant processing in order to impart flame retardancy, so that the change in touch, flame retardant durability and dyeing fastness are prevented from being deteriorated in building interior and exterior materials such as wallpaper or exterior finish material, It can be used for various purposes such as interior finishing materials for ships or vehicles.

1 is a test report commissioned by the Korea Institute of Fire Science and Technology for the heat release rate test of quasi-non-combustible fabrics prepared according to an embodiment of the present invention.
Figure 2 is the heat emission rate and heat release rate curve data of the test results of the Korea Institute of Fire Science and Technology of semi-combustible fabrics prepared according to an embodiment of the present invention.
3 is data related to the shape and dimensions of a sample of the non-combustible fabric prepared in accordance with an embodiment of the present invention to the Korea Institute of Fire Technology.
4 is a test report commissioned by the Korea Institute of Fire Science and Technology for the gas hazard test of semi-combustible fabrics prepared according to the embodiment of the present invention.
5 is a graph of the behavior of the exhaust temperature curve and the experimental rat of the test results of the Korea Institute of Fire Science and Technology of semi-combustible fabrics prepared according to an embodiment of the present invention.
Figure 6 is a shape and dimensions of the sample of the non-flammable fabric prepared in accordance with an embodiment of the present invention to request a gas hazard test to the Korea Fire Institute.

The present invention relates to a quasi-nonflammable double Raschel letter comprising a front layer, a back layer, and an intermediate layer between the front layer and the back layer, wherein the front layer is woven by flame retardant yarn or modified flame retardant work, and the middle layer is flame retardant yarn or It is composed of monofilament of modified flame retardant fabrication, and the back layer is made of semi-combustible yarn composed of short-fiber rayon fiber modified with flame retardancy by mixing flame retardant in spinning step and carbon fiber with carbon content of 55% or more by weight. While maintaining the characteristics of the double-latssel double cushion, breathability and pressure dispersibility.

The front layer is preferably woven in the form of a mesh to improve breathability, and if necessary, separate external surfaces when forming patterns such as printing, embossing, and flocking on the surface. Because it can have a beautiful effect even without the finishing work, it can be usefully used for interior and exterior materials of buildings, such as wallpaper or exterior finishing materials, interior finishing materials for ships or vehicles.

The intermediate layer forms a constant space between the front layer and the rear layer to provide sound insulation, heat insulation, and cushioning to provide cushioning and pressure dispersion to the double Rassel letter.

The fiber material constituting the front layer and the intermediate layer is not limited to use in the present invention as long as it is ordinary flame retardant yarn or modified flame retardant work, for example, fluorine-based polymer fibers such as polytetrafluoroethylene (PTFE), aramid, etc. Flame retardant yarn or polypropylene (PP), such as a wholly aromatic nylon fiber, polyimide fiber, polyvinyl chloride (PVC) fiber, polychlal fiber, modacryl fiber, novoloid fiber ), Modified flame retardants obtained by incorporating flame retardants into polymers such as polyethylene (PE), polyester, polyethylene terephthalate (PET), polybutylene terephthalate (PBT), and polyamide Can be.

If the fiber of the front layer and the middle layer is composed of a flame retardant material as described above, the fire resistance can be expected in the case of fire, but the letter using the material has a disadvantage of shrinking considerably when exposed to a flame, thereby preventing the letter from spreading the flame. It is difficult to anticipate the role of a firewall, and also involves the risk of causing secondary accidents by contraction of letters.

Therefore, it is required to have a flame retardant performance and hardly shrinkage even when exposed to a flame. For this purpose, in the present invention, a rayon short fiber and a carbon content modified to be flame retardant by incorporating a flame retardant in the spinning step as the fiber forming the rear layer. It is composed of carbon fiber with more than 55% by weight and uses flame retardant performance and semi-combustible yarn with small heat shrinkage.

The semi-combustible spun yarn is prepared by mixing and spinning 1 to 99% by weight of rayon short fibers and 1 to 99% by weight of carbon fibers containing flame retardant, and preferably 5 to 95% by weight of rayon short fibers. 5 to 95% by weight of fibers are mixed and spun, and one or two or more of the para-aramid short fibers, short teflon fibers or short silica fibers may be further included in the yarn.

The flame retardant rayon short fiber is a short fiber modified by adding a flame retardant in the spinning step of rayon, and has characteristics of flame retardancy, washing durability and dyeing, and 1 to 5 denier (denier) and a fiber length of 22 to 51 mm are suitable. .

However, if the flame retardant is added to the rayon short fibers, the flame retardancy is increased, but when the fabric using the flame retardant is not exposed to the flame, it does not satisfy the KFI (flammability performance standard) recognized by the Korean Fire Industry and Technology Institute, and there is a problem of shrinkage and damage.

In order to solve this problem, the flame retardant rayon short fibers are mixed with carbon fibers having 1 to 7 denier and 38 to 76 mm long fiber to prevent flame retardancy and to prevent shrinkage and damage.

Carbon fiber is a fiber made by heating and carbonizing organic fiber under oxygen-free conditions. Molecular arrangement and crystal change occur according to raw materials and processing temperature, and carbon hexagonal rings are formed in succession to form layered lattice. It is colored or gray.

Molecular weights such as oxygen, hydrogen and nitrogen are released during the heating process to reduce the weight. Therefore, it is lighter than metal but has superior strength and elasticity compared to metal, and has excellent heat resistance, impact resistance and chemical resistance.

These carbon fibers are obtained by heat treating the precursor raw material, and the precursor raw materials include cellulose, acrylic fiber, vinylon, pitch, and the like, and thermoplastic polymers such as aromatic polyamides and thermosetting resins such as phenol or fufuryl resins. Polymers are also used as precursors.

General carbon fiber (carbon fiber) is composed of more than 90% of the main component carbon, but the carbon fiber in the present invention includes carbonized carbon fiber (oxygenized carbon fiber) of 55% by weight or more, materials such as metals Due to the high density, the elastic modulus is only about 250 ~ 300㎬, but the carbon has a density close to 2 and the theoretical elastic modulus is 1,000 섬유, so the fibrous carbon can exert a high effect on the reinforcement of the polymer matrix.

Therefore, the process of processing the precursor fiber to the carbon fiber is required to produce a carbon fiber of high elastic modulus as well as a high carbon yield, which lowers the manufacturing cost of the semi-combustible spun yarn and improves the flame retardant performance, the overall fabric of the fabric using the yarn Provides the effect of improving physical properties.

Carbon fiber manufacturing process can be divided into precursor fiber stabilization process, carbonization process and graphitization process, the stabilization process is usually 400 ℃ or less, carbonization process is 1000 ~ 1500 ℃, graphitization process is heat treated to 2500 ~ 3000 ℃ Highly elastic carbon fibers are obtained.

In order to reduce the carbon content to less than 90%, carbonization fibers having a low carbon content can be obtained by omitting the graphitization process. The lower the heat treatment temperature of the carbonization process, the lower the carbon content of the carbon fibers, and also the strength and moisture absorption rate. However, the energy required for heat treatment is reduced, which lowers the manufacturing cost of carbon fiber.

The physical properties of carbon fiber vary in structure and physical properties depending on various factors such as heat treatment temperature, temperature increase rate, temperature increase step, chemical treatment of fiber surface and inert gas, which are applied during stabilization and carbonization process. The change is mainly influenced by the stabilization process, and when the carbonization process is exposed to high heat treatment temperature, the stabilization process determines whether the carbon fiber can maintain a chemically and physically stable structure.

The stabilization process is carried out in the temperature range below 400 ℃, the main pyrolysis occurs between 200 ~ 350 ℃ accompanied by heat shrink with a weight loss of 70 ~ 90%.

As the chemical structure changes with physical changes such as weight loss, fiber diameter reduction, fiber density and microstructure change during the pyrolysis process, it is important to select the optimal conditions for the stabilization process. It becomes an argument.

In the present invention, the precursor raw material is first heated to 400 ° C. at a rate of 140 to 160 ° C./hour in air, and then a stabilization process is performed. After that, carbon fiber is manufactured through a normal carbonization process or a carbonization process and a graphitization process under an oxygen-free atmosphere. do.

The stabilization process is carried out in air because the formation of a reactive atmosphere during pyrolysis can suppress the formation of tar, promote the dehydration reaction, and improve the overall physical properties such as elasticity of the carbon fibers.

When the temperature increase rate is less than 140 ℃ / hour, the improvement effect of the weight loss rate is not much greater than the temperature increase rate of 140 ℃ / hour, it takes a lot of working time, and if it exceeds 160 ℃ / hour, the weight reduction rate increases and the physical properties of the carbon fiber is lowered do.

As a flame retardant mixed in the modified flame retardant construction or flame retardant added to the production of flame retardant rayon short fibers, phosphoric acid, triphenyl phosphate, tricresyl phosphate, trichloroethyl phosphate, and trichloroethyl phosphate Phosphorus-based flame retardants, such as, but may be used, if the flame retardant that can be used in rayon to impart flame retardancy is not limited to use.

As the blending ratio of the carbon fiber in the spun yarn increases, flame retardancy, durability and form stability increase, and the amount of harmful gas generated decreases, while the spun yarn tends to be soft and stiff.

In order to compensate for this, one or two or more of paraaramid short fibers, teflon short fibers, and short silica fibers may be mixed with the spun yarn made of the rayon short fibers and carbon fibers.

Para-aramid fibers are aromatic polyamide fibers, in which amide bonds bind aromatic rings, such as benzene rings, to form polymeric polyamides. They are excellent in tensile strength, toughness and heat resistance, and exhibit high strength and high modulus.

In addition, para-aramid fibers are not burned or melted, the strength of the yarn increases as the mixing ratio increases.

Teflon fiber, a fluorine fiber, may be selected from fibers of polytetrafluoroethylene (PTFE), perfluoroalkoxy (PFA), fluoroethylenepropylene (FEP), and polyvinylidene fluoride (PVDF). Among them, PTFE is the most preferable, and the yarn containing it is characterized by excellent heat resistance, cold resistance and chemical resistance.

However, since the para-aramid fibers and the Teflon fibers are high in price, which increases the manufacturing cost of the spun yarn, it is necessary to reduce the manufacturing cost while improving the heat resistance by mixing the silica fibers.

Silica fiber contains 90 to 99% by weight of silicon dioxide (SiO ₂ ), 0.3 to 5.0% by weight of aluminum oxide (Al ₂ O ₃ ) and other trace elements, and withstands continuous use temperature of 1,000 ° C and instantaneous use temperature of 1,650 ° C. As a heat-resistant fiber that can be, a yarn containing silica fibers is characterized by maintaining its shape even at high heat.

Silica fiber has the advantages of excellent heat resistance, chemical resistance, electrical insulation, and no toxicity and skin irritation to the human body. On the other hand, when the fiber is severely broken and contains a lot of flexural strength and tensile strength, the fiber is easily broken and lost. The disadvantage is that spinning is difficult.

Therefore, the mixed amount of the para-aramid short fiber, teflon short fiber, and silica short fiber needs to be properly adjusted in consideration of heat resistance, strength, loss of fiber, and ease of spinning, and a mixed fiber composed of rayon short fiber and carbon fiber 10 to 70 parts by weight of at least one of para-aramid short fibers, teflon short fibers and short silica fibers is preferably added based on 100 parts by weight, and only one of the para-aramid short fibers, short teflon fibers and short silica fibers is added. 10 to 30 parts by weight when added, 10 to 50 parts by weight when two are added, 10 to 70 parts by weight is more preferable when all three are added.

The mixed para-aramid short fibers, short teflon fibers, short silica fibers are composed of short fibers of 1 to 7 days and 22 to 76 mm fiber length, and the heat resistance, strength and flexibility of the spun yarn increases as the mixing ratio increases.

As described above, the double laselle of the present invention is composed of a flame retardant material of the front layer, the middle layer, and the rear layer, and can have flame retardant performance while maintaining cushioning characteristics, breathability, and pressure dispersibility, which are inherent in the double laselle. Since the layer is composed of quasi-non-spinning yarns with a low heat shrinkage rate, the double raschel letter hardly shrinks in case of fire, thus acting as a firewall, thereby minimizing the spread of flame and minimizing property damage due to fire.

Hereinafter, a method of manufacturing a semi-nonflammable double raschel letter of the present invention will be described in detail.

First, a semi-combustible spun yarn composed of flame-retardant modified rayon short fibers and carbon fibers having a carbon content of 55% or more by weight is manufactured, and then a semi-combustible double-lasel letter is prepared by using double-lasel knitting machine together with flame retardant yarn or modified flame retardant work. do.

1) Semi-combustible spun yarn manufacture

1-1) Short Fiber Preparation Process

Flame-retardant rayon short fibers having a thickness of 1 to 5 days, 22 to 51 mm in length and containing a flame retardant and carbon fibers having a thickness of 1 to 7 days and a length of 38 to 76 mm Prepare.

The carbon fiber is produced by precursor materials such as cellulose, acrylic fiber, vinylon, pitch, thermoplastic polymer such as aromatic polyamide, and thermosetting polymer such as phenol or perfuryl resin through a stabilization process and a carbonization process, and increase carbon content. If you want to do so, go through the graphitization process.

The stabilization process is first made by heating the precursor fiber to 400 ℃ at a rate of 140 ~ 160 ℃ / hour in the air, and then through the normal carbonization process, graphitization process under the oxygen-free atmosphere to produce a carbon fiber.

The flame retardant can be used as long as it is a common flame retardant that can be used for rayon to impart flame retardancy, and the carbonization process and the graphitization process can be easily carried out by those skilled in the art having ordinary skill in the art. Since it is a well-known technique, in the present invention, specific limitations on the carbonization process and the graphitization process are not made.

1-2) Honta Process

1 to 99% by weight of the prepared flame retardant rayon short fiber and 1 to 99% by weight carbon fiber, preferably 5 to 95% by weight of flame retardant rayon short fiber and 5 to 95% by weight carbon fiber, first, rayon short fiber and carbon The fibers are fed into an automatic feeding machine, and the mixed fibers are manufactured through a vibration damper and a mixer.

Looking at the above process in more detail, a mixing process of mixing rayon short fibers and carbon fibers, an opening process of unwinding a large bundle of fibers and separating them into small tufts, a miscellaneous product, and a nepsil (nep) A cleaning process to remove mixed impurities such as yarn, and a lap formation process to create a lap having a uniform thickness and width.

In order to compensate for the decrease in the elasticity of the spun yarn when the content of the carbon fibers increases, one of the para-aramid short fibers, teflon short fibers, and short silica fibers in 100 parts by weight of the mixed fibers in which the rayon short fibers and the carbon fibers are mixed It is preferable to add and mix 10 to 70 parts by weight of the above, and if only one of the para-aramid short fibers, short teflon fibers and short silica fibers is added, 10 to 30 parts by weight, and 10 to 50 parts by weight if two are added Part, when all three kinds are added 10 to 70 parts by weight is more preferable.

1-3) carding process

The mixed fibers mixed in the blending process are introduced into a carding machine to remove miscellaneous goods contained in the fibers, and the fibers are constantly arranged in the longitudinal direction to form a sliver.

In the carding process, even if the wraps made in the Honta process are open and closed, they are completely separated one by one, and the miscellaneous products are not removed. Therefore, comb the fibers to separate them completely into a single column. Since the stretching operation in the process to proceed smoothly.

In other words, comb the fibers through a carding process to separate them into individual fibers (combing), remove miscellaneous items and neps from the fibers (settle), and stretch the fibers to some extent to straighten and parallelize them (stretch). Create a roughly uniform fiber bundle (faceplate sliver formation).

In addition, if you want to remove fiber debris or dust attached to the fiber and obtain a high-quality spun yarn with higher strength and uniformity, pass through the carding process sliver through a combing machine to pass You may.

1-4) Softening Process

Six to eight strands of the sliver manufactured in the carding process are simultaneously introduced into a drawing frame, and the draft ratio is 6 to 8 times to prepare a sliver with good uniformity.

In the case of a carding sliver produced through a carding process, the individual fibers in the sliver have been combed but not completely straightened, and are not oriented and arranged in parallel.

In addition, even in the facet sliver produced through the carding process and the facetling process, there is a nonuniformity between the slivers and non-uniformity between the slivers depending on the change in the weight of the wrap and the processing conditions in the carding machine and the carding machine.

In this way, when the yarn is made of slivers having uneven weight or low arrangement, the thickness fluctuation of the thread is large, resulting in an uneven yarn, and a large amount of hair is generated to make a yarn of high quality.

The softening process is the last process to correct the cause of this disinfectant during the manufacturing process of the yarn. The 6 ~ 8 slivers are combined to improve the uniformity, and the combined slivers are stretched to parallelize the fibers to improve the arrangement. Let's do it.

As described above, the rayon short fiber, the carbon fiber and the para-aramid short fiber, the Teflon short fiber, and the short silica fiber may be mixed in a blending process to perform lap blending. It is also possible to produce a sliver mixed with each of the slivers through a blending step and a carding step and then mixing them in a softening step.

1-5) Roving Process

Twisting while stretching the sliver manufactured in the softening process to produce a (roving).

There are many shortcomings in terms of quality of the draft mechanism, operation problems, and fungicides, so making the yarn with the sliver produced in the softening process has to reduce the line density by drawing the sliver with the thickness to make the thread.

Therefore, the sliver is stretched in the spinning process to reduce the thickness and give a slight twist, so that the yarn of the desired thickness can be released in the subsequent spinning process.

1-6) Spinning Process

The irradiation produced in the spinning process is stretched to the required thickness and twisted to give fiber bundles arranged side by side to entangle in three dimensions to maintain the strength of the yarn by increasing the focusing force between the fibers.

1-7) Plywood process

By combining two or more yarns produced in the spinning process, the strength of the yarn and the tensile strength and tear strength of the fabric using the same can be improved, and the number of strands and the twisting direction of the single yarn can be properly adjusted according to the use. .

2) Semi-nonflammable double raschel manufacturing

The quasi-non-flammable double raschel letter of the present invention can be manufactured using a double raschel knitting machine, the conventional flame retardant yarn or modified flame retardant work and the quasi-combustible spun yarn prepared above is wound on the canonical beam and then the beams are mounted on the double raschel knitting machine. .

Using the needle bar and guide, the front layer is woven into the mesh-type porous fabric using flame retardant yarn or modified flame retardant fabrication, and the back layer is woven using the quasi non-flammable yarn, and the monofilament of flame retardant yarn or modified flame retardant fabrication is used. An intermediate layer is formed to connect the front layer and the rear layer to each other to produce a double Rassel letter having a predetermined space in the intermediate layer.

If necessary, the surface of the front layer may be printed, embossed, or flocked to express a pattern or dye to express various colors, and to be flame-retardant and semi-combustible rather than post-flame-retardant to impart flame retardancy. Therefore, it is possible to prevent the touch change, flame retardant durability and dyeing fastness to be lowered, and can be used for various purposes such as interior or exterior building materials such as wallpaper or exterior finish material, interior finishing materials for ships or vehicles.

Hereinafter, the present invention will be described in more detail with reference to the following examples, comparative examples and test examples.

It is to be understood, however, that the invention is not to be construed as limited to the embodiments set forth herein, but is capable of modifications and equivalents within the spirit and scope of the invention. Will be apparent to those skilled in the art to which the present invention pertains.

≪ Example 1 >

First, the carbonization yield and carbon content according to the carbon fiber manufacturing method were examined.

Stabilization was performed by raising the cellulose which is a precursor fiber of carbon fiber to 400 ° C. in air at a rate of 150 ° C./hour, and then carbonizing by heating up to 1200 ° C. in an inert gas environment and then graphitizing by heating up to 2700 ° C. Fibers were prepared.

<Example 2>

In Example 1, the carbonized fibers were not graphitized, except that carbon fibers were prepared in the same manner as in Example 1.

&Lt; Comparative Example 1 &

In Example 1, a carbon fiber was manufactured in the same manner as in Example 1, except that the temperature increase rate of the stabilization process was increased to 400 ° C. at a rate of 130 ° C./hour.

Comparative Example 2

In Example 1, a carbon fiber was manufactured in the same manner as in Example 1, except that the temperature increase rate of the stabilization process was increased to 400 ° C. at a rate of 170 ° C./hour.

&Lt; Comparative Example 3 &

In Example 1, the fiber subjected to the stabilization process was carbonized by raising the temperature to 1000 ℃ in an inert gas environment and then not graphitized, except that the carbon fiber was prepared in the same manner as in Example 1.

&Lt; Test Example 1 >

The weight loss rate and carbon content of the carbon fibers prepared in Examples 1 and 2 and Comparative Examples 1 to 3 were measured and shown in Table 1 below.

The weight loss rate was expressed as a percentage after measuring the weight loss of the carbon fiber based on the precursor fiber weight using a chemical analysis scale, and the carbon content was measured using an element analyzer (CHN-1000, Leco, USA).

Example 1 Example 2 Comparative Example 1 Comparative Example 2 Comparative Example 3 Weight reduction rate (%) 72 65 71 77 62 Carbon content (% by weight) 98.1 58.6 99.1 95.7 51.6

In the results of Table 1, the weight loss rate was lower in Example 2 and Comparative Example 3, which did not perform the graphitization process, and Comparative Example 1 and Comparative Example 1 were comparatively low when the graphitization process was performed. Example 2 appears high, it can be seen that the lower the rate of temperature, the lower the weight reduction rate.

However, the difference between Example 1 and Comparative Example 1 is fine, and considering the production time of the carbon fiber, it is determined that Example 1 is more advantageous in terms of work efficiency.

In addition, in the carbon content, the higher the temperature increase rate in the stabilization process, the lower the Example 2 and Comparative Example 3, which was not subjected to the graphitization process, and Comparative Example 3, which had the lowest heat treatment temperature in the carbonization process, were the lowest.

That is, it is preferable to perform a stabilization process by raising the temperature at a rate of 150 ° C./hour in air after performing the flameproofing treatment as in Example 1 in that the yield of carbon fiber can be increased, and the carbon content is a low temperature rising rate. It can be seen that the higher the heat treatment at a higher temperature.

<Example 3>

In the carding process, flame retardant rayon short fibers and phosphorus flame retardants containing phosphoric acid are manufactured with slivers, respectively. The weight ratio was adjusted to 60%: 40% to proceed the softening process.

The carbon fiber was prepared by the method of Example 1, which can be most efficiently produced as a result of Test Example 1.

The sliver having undergone the softening process was manufactured by using a conventional spinning process, square process, and plywood process to produce quasi-non-flammable yarns having 10 cotton yarn number, and 300 g / m2 of warp yarn using warp weaving yarn as warp and weft yarns. Dobby Weaving was woven.

<Example 4>

In Example 3, the fabric was woven in the same manner as in Example 3, except that the weight ratio of flame retardant rayon short fibers to carbon fibers was adjusted to be 80%: 20%.

<Example 5>

In the carding process, a silica fiber is manufactured as a sliver, and the silica fiber is added to the mixed fiber of flame retardant rayon short fiber and carbon fiber in Example 3 so that the mixed fiber: silica fiber = 100 parts by weight: 30 parts by weight. Except that proceeded, weaving the fabric in the same manner as in Example 3.

<Example 6>

In the carding process, Teflon fibers are manufactured by a sliver, and the Teflon fibers are added to the mixed fibers of flame retardant rayon short fibers and carbon fibers in Example 3 such that the mixed fibers: Teflon fibers = 100 parts by weight: 30 parts by weight, and a softening process. Except that proceeded, weaving the fabric in the same manner as in Example 3.

&Lt; Example 7 >

In the carding process, the para-aramid fibers are manufactured with a sliver, and the para-aramid fibers are added to the mixed fibers of flame retardant rayon short fibers and carbon fibers in Example 3 such that the mixed fibers: para-aramid fibers = 100 parts by weight: 30 parts by weight. The fabric was woven in the same manner as in Example 3, except that the softening process was performed.

&Lt; Example 8 >

In Example 3, the fabric was woven in the same manner as in Example 3, except that the carbon fiber was manufactured and used in the method of Example 2.

&Lt; Comparative Example 4 &

300 g / m2 dobby with the yarns of warp and weft yarns made using a rapier weaving machine after producing yarns with 10 cotton yarns in a normal spinning yarn manufacturing process using ordinary rayon short fibers having 3 denier and 51 mm fiber lengths. Weaving the fabric.

The fabric was post-flammed with phosphoric acid, a phosphorus flame retardant.

&Lt; Comparative Example 5 &

In Comparative Example 4, the yarn was prepared using silica-containing rayon short fibers imparted flame retardancy by containing silica instead of the normal rayon short fibers, and accordingly, except that the flame retardant was not treated afterwards, The fabric was woven in the same way.

&Lt; Comparative Example 6 >

In Comparative Example 4, except that the general polyester short fibers having 1.5 denier, 38 mm fiber length instead of the regular rayon short fibers were used, weaving the fabric in the same manner as in Comparative Example 4 and then flame-retardant.

&Lt; Comparative Example 7 &

In Comparative Example 6, a spun yarn was prepared using flame retardant polyester short fibers provided with flame retardant by treating phosphoric acid, which is a phosphorus-based flame retardant, in place of ordinary polyester short fibers. The fabric was woven in the same manner as in Example 6.

&Lt; Comparative Example 8 >

In Example 3, the fabric was woven in the same manner as in Example 3, except that the carbon fiber was prepared and used in the method of Comparative Example 3.

&Lt; Test Example 2 &

The fabrics produced in Examples 3 to 8 and Comparative Examples 4 to 8 were evaluated for non-combustible and semi-combustible materials for interior decoration (Korea Fire Industry and Technology Institute) and flame retardant performance standards for building interior finishing materials (Notice of Ministry of Construction and Transportation 2006- No. 476, Ministry of Land, Transport and Maritime Affairs 2009-886) measured flame retardant performance according to KS F ISO 5660-1 and KS F 2271, which are semi-combustible materials testing methods. The results are shown in Table 2 below.

Test Items Example Comparative example How to measure 3 4 5 6 7 8 4 5 6 7 8 Total heat release
(MJ / ㎡) 3.67 3.71 2.49 2.39 2.87 6.54 9.35 8.69 20.6 22.7 7.12 KS F ISO 5660-1 Maximum heat release rate (200㎾ / ㎡
Overtime)
(second) 0 0 0 0 0 0 8.3 9.8 16.3 19.3 0 KS F ISO 5660-1 Cracks, holes, melting none none none none none none hole hole Melting Melting crack KS F ISO 5660-1 Laboratory rat
Stop time for action
(minute) 12.3 12.9 13.2 14.4 14.0 10.5 10.3 11.8 3.6 4.2 8.3 KS F 2271 Shrinkage rate
(%) 0.3 0.9 1.2 2.1 3.1 4.8 29.1 18.3 45.2 43.9 5.5 Actual measurement

According to Korean Industrial Standard KS F ISO 5660-1 [Combustion performance test-heat release, smoke generation, mass reduction rate-Part 1: heat release rate (cone calorimeter method)], the total amount of heat emitted during the heating test for 10 minutes is 8MJ / M 2 or less, the maximum heat release rate for 10 minutes does not exceed 200 mW / m 2 continuously for 10 seconds or more, and harmful cracks, holes, and melts on the fire-resistant material after heating for 10 minutes (in the case of composite materials, the cores are all melted, Including extinction).

Looking at the results of Table 2, the total heat release amount of 10 minutes of Examples 3 to 8 of the present invention is 7MJ / ㎡ or less, while Comparative Examples 4 to 7 all exceeded 8MJ / ㎡, the reference value, in particular Comparative Example 6, 7 indicates that the amount of heat released when the polyester fiber is burned in excess of 20 MJ / m 2 is large.

In addition, at the maximum heat release rate, Example and Comparative Example 8 did not exceed 200 mW / m 2, and Comparative Examples 4 and 5 were only satisfied with the test criteria of less than 10 seconds as 8.3 seconds and 9.8 seconds, but Comparative Example 6 And 7 were 16.3 seconds and 19.3 seconds, which were found to be unsuitable as semi-combustible materials for interior decoration above the standard.

In addition, it can be seen that after 10 minutes of heating, cracks or through-holes are formed or melted in the test specimens of the comparative example, so that the fire protection function cannot be performed in a fire.

1 shows the test results obtained by requesting the heat release rate test of the quasi-non-combustible fabrics prepared according to Examples 3 to 5 by the Korea Fire Institute of Technology, and FIG. 2 is a quasi-non-combustible manufactured according to Examples 3 to 5 above. The heat emission rate and heat release rate curve data are shown in the test results of the Korea Fire Institute.

FIG. 3 shows data related to the shape and dimensions of a sample of the quasi-non-flammable fabric prepared according to Examples 3 to 5, which was commissioned by the Korea Institute of Fire Industry and Technology. In the drawing, Test Sample 1 corresponds to Example 3, Test body 2 corresponds to Example 4, test body 3 to the fabric of Example 5.

In addition, in the gas hazard test of the Korean Industrial Standard KS F 2271, the average behavior stop time of the rats should be 9 minutes or more, and the test results of Examples 3 to 8 and Comparative Examples 4 and 5 satisfy the above criteria, but Comparative Examples 6 ~ 8 is 3.6 minutes, 4.2 minutes and 8.3 minutes, which is considered to be very fatal in case of fire.

4 shows the test results obtained by requesting the gas hazard test of the quasi-non-combustible fabrics prepared according to Examples 6 and 7, and the quasi-non-combustible manufactured according to Examples 6 and 7 in FIG. Exhaust temperature curves and experimental rat behavior graphs are shown among the results of the Korea Institute of Fire Science and Technology testing.

FIG. 6 shows data related to the shape and dimensions of a sample of the quasi-non-combustible fabrics manufactured according to Examples 6 and 7, and commissioned by the Korea Institute of Fire Industry and Technology. Test body 2 corresponds to the fabric of Example 7.

In addition, in the shrinkage rate after combustion, since the embodiment of the present invention is 0.3 to 4.8%, which is very small and does not melt without cracks and holes, it acts as a firewall in case of fire, thereby reducing the spreading rate of the flame to reduce property damage due to fire. In Comparative Example 8, except for Comparative Example 8, 29.1 to 45.2% shrinks and collapses, thus preventing the role of a firewall to reduce the spreading rate of the flame.

As described above, it can be seen that the semi-non-combustible fabrics of Examples 3 to 8 satisfy the non-combustible materials standards of the non-combustible and semi-combustible materials of the interior decoration and the flame retardant performance standards of the interior finishing material of the building.

&Lt; Example 9 >

Flame-retardant polyester fiber treated with phosphoric acid, a phosphorous flame retardant, and impregnated with flame retardant yarns. Mounted.

Using the needle bar and guide, the front layer is made of flame-retardant polyester fiber in the form of mesh, and the back layer is made of quasi non-flammable yarn in the form of plain weave, and the middle layer is the para-aramid monofilament that connects the front layer and the back layer to each other. Double Raschel letters were manufactured to form a space therein.

&Lt; Example 10 >

In Example 9, a double-Rassel letter was manufactured in the same manner as in Example 9 except that the back layer was woven with the quasi-non-flammable yarn prepared in Example 8 instead of the quasi-non-combustible yarn prepared in Example 3. .

&Lt; Comparative Example 9 &

In Example 9, a double-Rassel letter was prepared in the same manner as in Example 9 except that the back layer was woven from the flame retardant polyester fiber instead of the quasi-non-combustible yarn.

&Lt; Comparative Example 10 &

In Example 9, a double-Rassel letter was manufactured in the same manner as in Example 9, except that the back layer was woven with the quasi-non-flammable yarn prepared in Comparative Example 8 instead of the quasi-non-flammable yarn prepared in Example 3. .

&Lt; Comparative Example 11 &

The front layer was woven into a mesh form using the flame-retardant polyester fiber of Example 9, the rear layer was woven into a plain weave using a quasi non-flammable yarn of 10 cotton yarn number prepared in Example 3, the front layer The para-aramid monofilaments are alternately stacked vertically and vertically between the front and rear layers to fill an intermediate layer consisting of all four layers (quadrate), and then the warp or weft yarn when weaving the front and rear layers Weaves were interwoven with opposite wefts or warp yarns across the middle layer every 3 cm apart.

That is, the front layer and the rear layer fabrics are interwoven with each other in a size of 3 × 3 cm (width × length), and partitioned into square unit compartments, and inside the unit compartment, a space filled with an intermediate layer is formed. Space fabric fabric that is repeatedly formed as is produced.

<Test Example 3>

To evaluate the cushioning and elastic recovery of the letters and fabrics prepared in Examples 9, 10 and Comparative Examples 9-11 are shown in Table 3 below.

Cushionability of the letter or the fabric was cut to a size 10 × 10 cm and stacked 10 sheets on the table and then lightly pressed three times with the fingertips from the top of the sensory evaluation.

Elastic recovery power is placed on the stack of 10 sheets of letters or fabric, put the weight of 500g for 1 hour, then remove the weight, measured the recovery degree after 3 seconds, 10 seconds, 1 minute and compared with the thickness before the experiment as a percentage Indicated.

Example Comparative example 9 10 9 10 11 Cushioning ^{1 )} 8 7 8 7 7 Elastic recovery
(%) 3 seconds 85 83 84 83 82 10 seconds 95 92 94 91 91 1 minute 99 99 99 99 98

Note 1) 10: cushioning very good, 5: cushioning normal, 0: cushioning bad

As a result of Table 3, the cushion property and the elastic recovery force of Comparative Example 11 was evaluated slightly low, but the difference was not large.

<Test Example 4>

The air permeability of the letters and fabrics prepared in Examples 9 and 10 and Comparative Examples 9 to 11 were measured and shown in Table 4 below.

Air permeability refers to the penetration of air into the space in the fabric, that is, the perforation. The perforation of the fabric varies depending on the thickness and texture of the yarn. Proper breathability is required.

The distribution of space in double raschel letters affects many important properties of the fabric, such as heat retention, moisture resistance, water resistance, filterability, and air resistance.

The air permeability was measured five times according to KS K 0570-1997 Prazi method using air permeability tester (SJTK-100, Sejin Test Technology, Korea), and then the average value was shown. The difference in the amount of air flowing vertically through the specimen was calculated.

The specimen size at this time was 17x17 cm, and the differential pressure was 100 kPa.

Example Comparative example 9 10 9 10 11 Air permeability (cm 3 / min / cm 2) 263.1 270.6 255.8 258.4 136.7

As shown in Table 4, the air permeability of Examples 9 and 10 and Comparative Examples 9 and 10 made of a double raschel letter is 255.8 ~ 270.6 cm 3 / min / cm 2 It can be seen that the breathability is very excellent, Comparative Example 11 The air permeability of is 136.7, which is measured relatively low, indicating that the air permeability is greatly reduced.

&Lt; Test Example 5 >

After firing the letters and fabrics prepared in Examples 9 and 10 and Comparative Examples 9 to 11, the shrinkage rates before and after combustion were measured and the results are shown in Table 5 below.

Example Comparative example 9 10 9 10 11 Shrinkage (%) 4.4 4.8 27.2 29.5 21.8

In the contraction rate before and after combustion, the embodiment of the present invention is very small, such as 4.4% and 4.8%, which can act as a firewall to reduce the spread rate of the flame in case of fire, thereby reducing property damage due to fire. In other words, it is contracted to 29.5% and 21.8%, and the shape collapses. Therefore, the role of the firewall to reduce the spread rate of the flame is impossible.

In addition, the double-Rassel letters of Examples 9 and 10 were dyed in various colors using reactive dyes, and flame retardant durability and color fastness were confirmed. As a result, double-Rassel letters according to the present invention were dyed. By expressing a variety of colors, there is an advantage that can prevent the touch change and flame retardant durability and dye fastness deterioration, which is a problem of rear flame retardant.

As described above, the quasi-non-combustible double-lasel letter according to the present invention is manufactured using a flame-retardant fiber as a yarn, so that the cushioning, breathability, and pressure dispersibility, which are characteristics of the double-lasel, can be provided with flame retardancy without deterioration. Shrinkage is less than 5%, which can act as a firewall in case of fire, reducing the spread rate of flame, thereby reducing property damage caused by fire and minimizing human injury.

In addition, the double-Rassel letter of the present invention is made of flame retardant and semi-flammable fibers rather than post-flame retardant processing in order to impart flame retardancy, so that the change in touch, flame retardant durability and dyeing fastness are prevented from being deteriorated in building interior and exterior materials such as wallpaper or exterior finish material, It can be used for various purposes such as interior finishing materials for ships or vehicles.

Claims (7)

A front layer, a back layer, and an intermediate layer formed between the front and back layers,
The front layer is woven by flame retardant yarn or modified flame retardant construction,
The intermediate layer is made of a monofilament of flame retardant yarn or modified flame retardant construction,
The back layer is a semi-non-flammable double-Rassel letter woven from a spun yarn composed of rayon short fibers modified by flame retardancy by mixing flame retardants in a spinning step and carbon fibers having a carbon content of 55% by weight or more. The method according to claim 1,
The flame retardant yarn of the front layer and the middle layer is at least one selected from the group consisting of polytetrafluoroethylene fiber, aramid fiber, polyimide fiber, polyvinyl chloride fiber, polycral fiber, modacryl fiber and novoroid fiber,
The modified flame retardant fabrication of the front layer and the intermediate layer is prepared by incorporating and spinning a flame retardant to at least one polymer selected from the group consisting of polypropylene, polyethylene, polyester, polyethylene terephthalate, polybutylene terephthalate, polyamide Semi-non-combustible double rassel letter characterized in that. The method according to claim 1,
The backing yarn of the back layer of 1 to 5 denier modified by flame retardancy in the spinning step using a flame retardant, 5 to 95% by weight of rayon short fibers of 22 to 51 mm and 1 to 7 denier, 38 to 76 mm of fiber length A quasi-nonflammable double raschel letter comprising 5 to 95 weight percent carbon fiber. The method according to claim 3,
10 to 70 parts by weight of at least one selected from the group consisting of 1 to 7 daiers, para-aramid short fibers, teflon short fibers and short silica fibers to 100 parts by weight of the spun yarn is added. Zune nonflammable double rassel letter. The method according to claim 1,
The carbon fiber is a carbon fiber precursor raw material in the air at a rate of 140 ~ 160 ℃ / hour to 400 ℃ to perform a stabilization process, and then to be produced through a carbonization process or a carbonization process and a graphitization process under an oxygen-free atmosphere Semi-non-flammable double rassel letter featuring. The method according to claim 5,
The precursor raw material is a semi-combustible double raschel letter, characterized in that at least one selected from the group consisting of cellulose, acrylic fiber, vinylon, pitch, aromatic polyamide, phenol and perfuryl resin. The method according to any one of claims 1 to 6,
The flame retardant is a semi-combustible double raschel letter, characterized in that at least any one selected from the group consisting of phosphoric acid, triphenyl phosphate, tricresyl phosphate and trichloroethyl phosphate.

Images