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Suede-tone flame-retardant union cloth

a flame-retardant union and fabric technology, applied in textiles, looms, weaving, etc., can solve the problems of poor design other than color, poor flame retardancy, and inability to meet the needs of tanned leather, and achieve excellent flame retardancy, good flame retardancy, and good texture

Inactive Publication Date: 2014-05-15
KANEKA CORP
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

The present invention is related to a suede-like flame-retardant union fabric that exhibits excellent design and favorable texture. It is comfortable, has high flame retardance, and is self-extinguishing even when exposed to flame. This fabric is particularly useful as an upholstery fabric for products such as chair covers, as it prevents ignition of the internal filling when exposed to flame. The fabric comprises warps and wefts, with the warps including polyester-based yarn and the wefts containing a spun yarn that contains at least 70 weight parts of a cellulosic fiber and a spun yarn that contains a flame retardant-containing halogen-containing fiber. The spun yarns are interwoven. The flame-retardant performance of this fabric is superior to that of a suede-like fabric made from polyester fiber. The fabric can be raised to a suede-like appearance by using ultrafine fibers or a mechanically raising step.

Problems solved by technology

Conventional tanned leather that is produced by raising the back face of leather with sandpaper or the like is not reasonable in price.
Furthermore, as it is a natural product, the quality tends to vary, and the design other than the color is poor.
However, in a case of adhering a flame retardant to the surface of the cloth for the purpose of improving flame retardance, the surface becomes whitened or tacky.
The flame-retardant performance is degraded over time due to the sunlight, moisture absorption and the like.
The flame-retardant effect is lost due to removal of the flame retardant by water washing or dry cleaning.
And for example, for ensuring the flame retardance of a chair using urethane foam, a large quantity of flame retardant is required.
As a result, the design and the comfort are restricted and the cost cannot be suppressed, and thus, it has been impossible to attain a satisfactory effect.
However, a cloth using the flame-retardant polyester-based fiber tends to develop a larger bore due to the melting of the polyester-based fiber at the time of combustion.
When the cloth is applied to a chair using urethane foam, it causes ignition of the urethane foam.
That is, the flame-retardant polyester-based fiber alone is insufficient to ensure flame retardance of a textile for upholstering a chair.
Furthermore, the fabric easily bores during the combustion due to the melt of the polyester-based fiber and shrinkage and / or thermal decomposition of the flame-retardant acrylic fiber.
As a result, the flame retardance is insufficient, or it is required to use polyester-based fiber for the conjugated fiber for the blended yarn.
Namely, the flame-retardant acrylic fiber cannot be used for general purpose in the textile for upholstering a chair.
However, when it is burned in a state upholstering the urethane foam or the like of a chair, it easily bores due to shrinkage of the fiber similarly to other acrylic fibers, which causes ignition of the urethane foam.
Namely, the crosslinked high flame-retardant acrylic fiber alone cannot ensure sufficient flame retardance.
However, since the cloth has insufficient flame retardance, it is not suitable for application to an interior decoration material.

Method used

the structure of the environmentally friendly knitted fabric provided by the present invention; figure 2 Flow chart of the yarn wrapping machine for environmentally friendly knitted fabrics and storage devices; image 3 Is the parameter map of the yarn covering machine
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Examples

Experimental program
Comparison scheme
Effect test

example 1

Shrinkage Rate in Fabric Weft Direction

[0064]A shrinkage rate in the weft direction for each fabric was calculated through the equation below (Equation 1). Here, “C” indicates that the shrinkage rate in the fabric weft direction is at least 20%; “B” indicates that the shrinkage rate is not less than 10% and less than 20%; and “A” indicates that the shrinkage rate is less than 10%. If the shrinkage is great, the weight of the textile per unit area is increased due to the shrinkage, and textile becomes stiff to touch.

[Shrinkage rate (%) in fabric weft direction]=([fabric greige width (150 cm)]−[fabric width after treatment in pressurized hot water and drying])×100 / [fabric greige width (150 cm)]  (Equation 1)

example 2

Evaluation of Flame Retardance

[0065]A polyurethane foam 7.5 cm in thickness and 22 kg / m3 in density (Model 360S manufactured by TOYO TIRE & RUBBER CO., LTD.) was covered with a fabric mentioned below so as to be subjected to a test for flame retardance of seating for household use in England, in conformity with BS 5852:1990 Source 1. The Source1 is described in standard No. BS 5852:1990 “Methods of test for assessment of the ignitability of upholstered seating by smouldering and flaming ignition sources” of the British Standards.

[0066]In the flame retardance assessment, the size of the bores formed due to the combustion in the test was measured twice in the fabric warp direction. “A” indicates that the size of the bore did not exceed 2 cm in any of the measurements. “B” indicates that the size of the bore exceeded 2 cm, but the urethane foam did not catch fire. “C” indicates that the size of the bore exceeded 2 cm, and the urethane foam caught and spread fire.

production example 1

Production of Flame Retardant-Containing Halogen-Containing Fibers

[0067]49.5 wt % of acrylonitrile, 49.5 wt % of vinylidene chloride, and 1.0 wt % of sodium of styrenesulfonate were polymerized to obtain a halogen-containing copolymer. This halogen-containing polymer was dissolved in acetone so as to obtain a polymer concentration of 27 wt %. To the polymer in the thus obtained polymer solution, 3 weight parts of antimony trioxide , 10 weight parts of antimony trioxide , 30 weight parts of antimony trioxide , 3 weight parts of zinc stannate , and 8 weight parts of antimony pentoxide were added respectively to prepare dopes. Each of these dopes was extruded out through a nozzle 0.08 mm in caliber and having 300 holes into a 30 wt % aqueous solution of acetone, washed with water and dried. Subsequently, the extruded filament was stretched to be tripled at 120° C., and treated with heat at 150° C. for 5 minutes, to which a finishing oil for spinning was applied. The stretched filamen...

the structure of the environmentally friendly knitted fabric provided by the present invention; figure 2 Flow chart of the yarn wrapping machine for environmentally friendly knitted fabrics and storage devices; image 3 Is the parameter map of the yarn covering machine
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Abstract

The present invention provides, at a low cost, a suede-like flame-retardant union fabric which exhibits excellent design and texture, which is comfortable, and which has high flame retardance. The suede-like flame-retardant union fabric is formed of warps and wefts, in which the warps are raised on at least one face of the fabric. In the suede-like flame-retardant union fabric, the warps include a polyester-based yarn, and the wefts include a spun yarn (A) that contains at least 70 wt % of a cellulosic fiber and a spun yarn (B) that contains a flame retardant-containing halogen-containing fiber containing 3 to 50 weight parts of a flame retardant with respect to 100 weight parts of halogen-containing fibers. The spun yarn (A) and the spun yarn (B) used as the wefts are alternately interweaved.

Description

TECHNICAL FIELD[0001]The present invention relates to a suede-like flame-retardant union fabric having excellent texture.BACKGROUND ART[0002]Recently, there has been more demand for ensuring safety of food, clothing and shelter, and it enhances the demand for flame-retardant materials. Under the circumstances, the demand for interior decoration materials provided with flame retardance compatible with its design has been increased.[0003]Conventional tanned leather that is produced by raising the back face of leather with sandpaper or the like is not reasonable in price. Furthermore, as it is a natural product, the quality tends to vary, and the design other than the color is poor.[0004]For these reasons, suede-like cloths that are called artificial leather or synthetic leather have been used for the interior decoration materials. The suede-like cloths are produced by forming fine naps on the surface of a woven fabric, a knitted fabric or a nonwoven fabric so as to resemble leather.[0...

Claims

the structure of the environmentally friendly knitted fabric provided by the present invention; figure 2 Flow chart of the yarn wrapping machine for environmentally friendly knitted fabrics and storage devices; image 3 Is the parameter map of the yarn covering machine
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Application Information

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Patent Type & Authority Applications(United States)
IPC IPC(8): D03D15/12D06C27/00
CPCD06C27/00D03D15/12D10B2201/20Y10T442/3285D03D15/513
Inventor HAGI, HIROYASU
Owner KANEKA CORP