Flame-retardant fiber composite and fabric produced therefrom

Abstract

The present invention relates to a flame resistant fiber composite obtained by compounding: 20 to 85% by weight of a fiber (A) containing 0.5 to 50 parts by weight of an Sb compound to 100 parts by weight of a polymer containing halogen atom of not less than 17% by weight; 5 to 80% by weight of a heat-resistant fiber (B); 0 to 40% by weight of a cellulosic fiber (C); and 0 to 40% by weight of an inflammable fiber (D). Use of the composite in furniture, beddings, etc. in house increasingly improves flame resistance of materials, enabling use in fields requiring advanced flame resistance.

Description

TECHNICAL FIELD [0001] The present invention relates to an inexpensive and advanced flame resistant fiber composite for furniture and beddings that can solve difficult problems for conventional flame resistant fiber composites, that is, improved flame resistance of bedding products; further improved processability and bulkiness; and satisfactory processability, touch, feeling, and sensuousness, and to a fabric produced using the flame resistant fiber composite. BACKGROUND ART [0002] Flame resistance is preferably given to materials used for furniture, beddings, etc. in a house for prevention of fire. Since flammable materials, such as cotton and urethane foams, are used for comfort in use of furniture or beddings, prevention of flaming to the flammable materials over a long period of time is important for fire prevention. In addition, the flame retardant materials to be used must not impair comfort or sensuousness of the furniture or beddings in use. Although various flame resistant...

AI Technical Summary

Benefits of technology

[0006] The present invention aims at improving difficult problems for conventional flame resistant fiber composites to solve, that is, flame resistance of bedding products, and at obtaining inexpensive and advanced flame resistant fiber composites used for furniture and beddings, having more improved processability and bulkiness that found in conventional products, satisfactory touch and feeling, and sensuousness.

Problems solved by technology

Although various flame resistant fibers and flame retardants have so far been examined, materials fully having these advanced flame resistance and requirements for materials for furniture and beddings have not yet been realized.

A technique of coating of flame retardants to cotton cloths, that is, what is called “additional processing flame retardation” is now being used, but there are problems, such as in uniformity of application of flame retardants, hardening of cloth by means of application, omission by washing, and safety of health.

In addition, although it is known that fabrics including fibers obtained using high polymers comprising copolymerized halogen has outstanding sensuousness and flame resistance, they continue burning in the case of power burner combustion and cannot maintain the structure thereof, and as a result, they give inadequate fire-resistant performance for preventing flaming to cotton and urethane foams that are used for the above-mentioned beddings and furniture.

Although cloths obtained from the heat-resistant fibers have outstanding flame resistance, they have only poor power for preventing combustion of other non-flame resistant natural fibers and chemical fibers, and therefore materials obtained from those materials having been compounded only demonstrate inadequate flame resistance.

Inevitably, there arise problems that extremely expensive materials made only from heat-resistant fibers can be used.

In addition, heat-resistant fibers have problems of difficulty in production of colored patterns having high sensuousness resulting from problems of unsatisfactory processability at the time of filament opening, poor moisture absorptivity, or feeling and poor dye affinity.

However, this technique has following problems as a flame resistant fiber composite: difficulty in processing in manufacturing of nonwoven fabrics, and inadequate bulkiness in a quilting process when using as a nonwoven fabric, in order to prevent flaming to urethanes used for furniture or bedding products; problems in sensuousness caused by poor feeling of gloss and poor coloring property resulting from inclusion of fibers comprising a large quantity of added flame retardant; and inadequate fire-resistant performance for preventing flaming to cotton and urethane foams used for the above-mentioned beddings and furniture, in prolonged exposure to intense flame, while having self-extinguishing property in case of a source of fire being kept away.