Flame retardant fabric and protective clothing using the same

Abstract

The present invention relates to a flame-retardant fabric comprising acrylic fiber, at least one regenerated cellulose fiber selected from flame-retardant rayon fiber and lyocell fiber, and polyimide fiber. The flame-retardant fabric comprises 26-79% by weight of acrylic fiber, 18-48% by weight of regenerated cellulose fiber, and 3-26% by weight of polyimide fiber. The polyimide fiber has a fiber length of 45-127 mm and a char length of 50 mm or less as measured by a flammability test according to GB / T 5455-1997. The present invention also relates to protective clothing incorporating the flame-retardant fabric. This provides a flame-retardant fabric exhibiting excellent flame retardancy, exhibiting a short char length in a flammability test, and protective clothing incorporating the fabric.

Description

Technical Field

[0001] The present invention relates to flame-retardant fabric and protective clothing using the same. Background Art

[0002] Fires and other accidents sometimes occur at work sites in the petroleum, petrochemical, coal mining, power, and welding industries, and dust explosions and other accidents sometimes occur at work sites in metal processing industries. Therefore, protective clothing worn at such work sites is required to be flame retardant.

[0003] Various flame-retardant fabrics for protective clothing have been proposed. For example, Patent Document 1 describes a fabric primarily composed of aromatic polyamide fibers, such as para-aramid fibers or meta-aramid fibers. However, the high cost of aromatic polyamide fibers has hindered the widespread adoption of safety products. Meanwhile, Patent Document 2 describes a flame-retardant fabric containing modacrylic fibers, cellulose fibers, and polyimide fibers.

[0004] Prior art literature

[0005] Patent Literature

[0006] Patent Document 1: Japanese Patent Application No. 2014-525520

[0007] Patent Document 2: China Patent Application Publication No. 105926097 Summary of the Invention

[0008] Problems to be solved by the invention

[0009] However, in the case of the flame-retardant fabric described in Patent Document 2, the char length may become long in a combustion test, and further improvement of flame retardancy has been demanded.

[0010] The present invention provides a flame-retardant fabric having a short char length in a combustion test and good flame retardancy, and protective clothing using the same.

[0011] Means for solving problems

[0012] The present invention relates to a flame-retardant fabric, characterized in that it is a flame-retardant fabric containing acrylic fibers, one or more regenerated cellulose fibers selected from flame-retardant rayon fibers and lyocell fibers, and polyimide fibers. The flame-retardant fabric contains 26 to 79 weight percent of acrylic fibers, 18 to 48 weight percent of regenerated cellulose fibers, and 3 to 26 weight percent of polyimide fibers. The polyimide fibers have a fiber length of 45 to 127 mm and a char length of 50 mm or less as measured by a flammability test based on GB / T 5455-1997.

[0013] Furthermore, the present invention relates to a protective clothing characterized by using the flame-retardant fabric.

[0014] Effects of the Invention

[0015] The present invention can provide a flame-retardant fabric having a short char length in a combustion test and excellent flame retardancy, and protective clothing using the same. DETAILED DESCRIPTION

[0016] The inventors of the present invention conducted intensive research to improve the flame retardancy of flame-retardant fabrics containing acrylic fibers, cellulose fibers, and polyimide fibers. As a result, they surprisingly discovered that by including acrylic fibers, flame-retardant rayon fibers and / or lyocell fibers, and polyimide fibers in fabrics in specified amounts, and by adjusting the polyimide fiber length to 45 to 127 mm, the char length of the fabrics in combustion tests was shortened, specifically to 50 mm or less. In particular, they discovered that by adjusting the polyimide fiber length to 45 mm or greater, the char length of the fabrics in combustion tests was shortened, specifically to 50 mm or less, even when the polyimide content was low. In the present invention, "char length" can be measured using a flammability test based on GB / T 5455-1997. In the present invention, "GB" refers to the Chinese national standard.

[0017] The inventors have discovered that, specifically, in flame-retardant fabrics made from spun yarn containing acrylic fiber, flame-retardant rayon fiber and / or lyocell fiber, and polyimide fiber, when the blending ratios of each fiber are the same, adjusting the polyimide fiber length to 45 to 127 mm significantly shortens the char length in a combustion test, significantly improving flame retardancy. Previously, improving flame retardancy in flame-retardant fabrics primarily involved adjusting the type and blending ratio of the fibers imparting flame retardancy. The discovery that fiber length influences flame retardancy is groundbreaking. Adjusting the polyimide fiber length within a specified range in fabrics, particularly those using spun yarn, significantly shortens the char length in a combustion test, representing an unexpected innovation for those skilled in the art.

[0018] The flame-retardant fabric comprises 26-79% by weight of acrylic fiber, 18-48% by weight of regenerated cellulose fiber selected from flame-retardant rayon fiber and lyocell fiber, and 3-26% by weight of polyimide fiber. From the perspectives of cost and flame retardancy, the flame-retardant fabric preferably comprises 44.5-79% by weight of acrylic fiber, 18-48% by weight of regenerated cellulose fiber selected from flame-retardant rayon fiber and lyocell fiber, and 3-7.5% by weight of polyimide fiber.

[0019] Specifically, the flame-retardant fabric can be formed from a spun yarn containing 26-79% by weight of acrylic fiber, 18-48% by weight of regenerated cellulose fiber selected from flame-retardant rayon fiber and lyocell fiber, and 3-26% by weight of polyimide fiber. From the perspective of cost and flame retardancy, the flame-retardant fabric is preferably formed from a spun yarn containing 44.5-79% by weight of acrylic fiber, 18-48% by weight of regenerated cellulose fiber selected from flame-retardant rayon fiber and lyocell fiber, and 3-7.5% by weight of polyimide fiber. The spun yarn can be produced using a known spinning method. The spinning method is not particularly limited, and examples thereof include ring spinning, air spinning, and air jet spinning.

[0020] The polyimide fibers have a fiber length of 45 to 127 mm. A fiber length of 45 mm or greater improves flame retardancy and significantly reduces the char length of the fabric in a combustion test. A fiber length of 127 mm or less enables production of spun yarn using conventional spinning equipment, resulting in excellent productivity. From the perspectives of flame retardancy and productivity in the spinning process, the polyimide fibers preferably have a fiber length of 45 to 76 mm, more preferably 45 to 64 mm, and even more preferably 45 to 55 mm.

[0021] The polyimide fibers are not particularly limited, and for example, polyimide fibers formed from a polyimide obtained by polymerizing a tetracarboxylic acid component and a diamine component can be preferably used.

[0022] As the tetracarboxylic acid component, for example, tetracarboxylic dianhydride etc. can be mentioned. As tetracarboxylic dianhydride, there is no particular limitation, for example, 3,3',4,4'-biphenyltetracarboxylic dianhydride (BPDA), pyromellitic anhydride (PMDA), oxydiphthalic anhydride (ODPA) etc. can be suitably used. Tetracarboxylic dianhydride can be used alone or in combination of two or more.

[0023] As the diamine component, for example, a diisocyanate compound, a diamine compound, etc. can be cited. As the diisocyanate compound, there is no particular limitation, for example, 2,4-toluene diisocyanate, 2,5-toluene diisocyanate, 2,6-toluene diisocyanate, etc. can be suitably used. The diamine compound is preferably an aromatic diamine compound. As the aromatic diamine compound, there is no particular limitation, for example, p-phenylenediamine (PPD), 2,2'-dimethyl-4,4'-diaminobiphenyl (m-tolidine), 4,4'-diaminodiphenyl ether (ODA), 3,4'-diaminodiphenyl ether, 2,2'-bis(trifluoromethyl)benzidine, etc. can be suitably used. One diamine component can be used alone, or two or more can be used in combination.

[0024] The flame-retardant fabric is not particularly limited, but from the perspective of flame retardancy and cost, it preferably contains 3 to 7.5% by weight of polyimide fiber, more preferably 4 to 7% by weight, further preferably 4.5 to 6.5% by weight, and most preferably 5 to 6.5% by weight.

[0025] As the polyimide fiber, for example, commercially available products such as ASPI (registered trademark) polyimide fiber manufactured by Jiangsu Aoshen Hi-Tech Materials Co., Ltd. can be used.

[0026] The acrylic fiber is preferably formed from an acrylonitrile copolymer copolymerized with 35 to 85% by weight of acrylonitrile and 15 to 65% by weight of other components. As other components, from the perspective of flame retardancy, it is preferred to use one or more selected from halogen-containing vinyl monomers and halogen-containing vinylidene monomers. The acrylonitrile content in the acrylonitrile copolymer is more preferably 35 to 65% by weight. The content of the halogen-containing vinyl monomer and / or the halogen-containing vinylidene monomer in the acrylonitrile copolymer is more preferably 35 to 65% by weight. The acrylonitrile copolymer may further contain a monomer containing a sulfonic acid group. The content of the monomer containing a sulfonic acid group in the acrylonitrile copolymer is preferably 0 to 3% by weight.

[0027] The above-mentioned acrylonitrile-based copolymer preferably contains: 35 to 85 weight % of acrylonitrile, 15 to 65 weight % of one or more halogen-containing monomers selected from halogen-containing vinyl monomers and halogen-containing vinylidene monomers, and 0 to 3 weight % of a monomer containing a sulfonic acid group, and more preferably contains: 40 to 75 weight % of acrylonitrile, 24.5 to 60 weight % of one or more halogen-containing monomers selected from halogen-containing vinyl monomers and halogen-containing vinylidene monomers, and 0.5 to 3 weight % of a monomer containing a sulfonic acid group.

[0028] When the acrylonitrile content in the acrylonitrile-based copolymer is 35 to 85% by weight, the physical properties of the acrylic fiber are good, and further, the physical properties of the flame-retardant fabric containing the acrylic fiber are also good.

[0029] When the content of the halogen-containing vinyl monomer and / or the halogen-containing vinylidene monomer in the acrylonitrile-based copolymer is 15 to 65% by weight, the flame retardancy of the acrylic fiber is good, and the flame retardancy of the flame-retardant fabric containing the acrylic fiber is also good.

[0030] The halogen-containing vinyl monomer is not particularly limited, and examples thereof include vinyl chloride and vinyl bromide. The halogen-containing vinylidene monomer is not particularly limited, and examples thereof include vinylidene chloride and vinylidene bromide. These halogen-containing vinyl and halogen-containing vinylidene monomers may be used alone or in combination of two or more.

[0031] The monomer containing the sulfonic acid group is not particularly limited, and examples thereof include methacrylic acid, allyl sulfonic acid, styrene sulfonic acid, 2-acrylamide-2-methylpropane sulfonic acid, and salts thereof. Among the above, examples of salts include sodium salts, potassium salts, and ammonium salts, but are not limited to these salts. These monomers containing sulfonic acid groups may be used alone or in combination of two or more. Sulfonic acid group-containing monomers may be used as needed, but excellent production stability in the spinning process is achieved as long as the content of the sulfonic acid group-containing monomer in the acrylonitrile-based copolymer is 3% by weight or less.

[0032] The acrylic fiber preferably contains an antimony compound. The content of the antimony compound in the acrylic fiber is 3.9 to 20% by weight, preferably 4.2 to 18% by weight, more preferably 4.5 to 16% by weight, and even more preferably 4.7 to 14% by weight, relative to the total weight of the fiber. When the antimony compound content is within this range, the char length in a combustion test is more easily shortened, and the afterglow time is also shortened.

[0033] The antimony compound is not particularly limited, but is preferably one or more selected from antimony trioxide, antimony tetroxide, and antimony pentoxide in view of production stability in the spinning process.

[0034] For example, from the perspectives of strength and productivity in the spinning process, short fibers with a fiber length of 30 to 127 mm are preferably used as acrylic fibers, preferably 45 to 127 mm, more preferably 45 to 76 mm, and even more preferably 45 to 64 mm. The acrylic fibers preferably have a fiber length approximately equivalent to that of polyimide fibers. This improves spinnability and enhances yarn quality, such as strength, thereby enhancing the physical properties of the flame-retardant fabric.

[0035] From the viewpoint of flame retardancy and heat resistance, the flame-retardant fabric preferably contains 44.5 to 65% by weight of the acrylic fiber, more preferably 50 to 65% by weight, and even more preferably 50 to 60% by weight.

[0036] The flame retardant rayon fiber is preferably a rayon fiber containing a phosphorus flame retardant. The phosphorus flame retardant is not particularly limited, and examples thereof include phosphate compounds, halogenated phosphate compounds, condensed phosphate compounds, polyphosphate compounds, and polyphosphate compounds. The flame retardant rayon fiber containing the phosphorus flame retardant is not particularly limited, and for example, it preferably contains 0.5% by weight or more of the phosphorus flame retardant relative to the total weight of the fiber, and more preferably contains 0.8% by weight or more. As the flame retardant rayon fiber containing the phosphorus flame retardant, for example, the flame retardant rayon "Lenzing FR (registered trademark)" manufactured by Lenzing, the flame retardant rayon "JWELL FR (trademark)" manufactured by Jilin Chemical Fiber Company, and other commercially available flame retardant rayon fibers can also be used.

[0037] The flame-retardant fabric contains at least 0.3% by weight of phosphorus, preferably at least 0.4% by weight, and more preferably at least 0.5% by weight, relative to the total weight of the fabric. When the phosphorus content in the flame-retardant fabric is 0.3% by weight or greater, the char length is more easily shortened, further improving flame retardancy. While there is no particular upper limit for the phosphorus content in the flame-retardant fabric, it is preferably 1.1% by weight or less relative to the total weight of the fabric to further shorten the char length. The phosphorus content in the flame-retardant fabric can be measured using fluorescent X-ray analysis.

[0038] In order to further improve flame retardancy, the flame-retardant fabric preferably contains flame-retardant rayon fibers as the regenerated cellulose fibers when containing acrylic fibers formed of an acrylonitrile-based copolymer obtained by copolymerizing acrylonitrile and a halogenated vinyl monomer.

[0039] The flame-retardant fabric can be provided with excellent hand feel and hygroscopicity while improving flame retardancy by containing the regenerated cellulose fiber in addition to the polyimide fiber and the acrylic fiber.

[0040] From the viewpoint of flame retardancy and hand feel, the flame-retardant fabric preferably contains 18 to 45% by weight of the regenerated cellulose fiber, and more preferably 20 to 40% by weight.

[0041] For example, from the perspectives of strength and spinning process productivity, the flame-retardant rayon fibers and lyocell fibers can suitably use staple fibers with a fiber length of 30 to 127 mm, preferably 45 to 127 mm, more preferably 45 to 76 mm, and even more preferably 45 to 64 mm. The flame-retardant rayon fibers and lyocell fibers preferably have a fiber length roughly equivalent to that of polyimide fibers. This improves spinnability, enhances silk properties such as strength, and further enhances the physical properties of the flame-retardant fabric. The acrylic fibers, flame-retardant rayon fibers, and lyocell fibers more preferably have a fiber length roughly equivalent to that of polyimide fibers.

[0042] The flame-retardant fabric may contain other fibers within a range that does not impair the objectives and effects of the present invention. Examples of other fibers include conductive fibers, nylon fibers, and polyester fibers. The flame-retardant fabric may contain other fibers in an amount of 5% by weight or less, 3% by weight or less, or 1% by weight or less.

[0043] For example, from the perspectives of strength and productivity in the spinning process, the other fibers can preferably have a staple length of 30 to 127 mm. From the perspective of productivity in the spinning process, the staple length is preferably 45 to 127 mm, more preferably 45 to 76 mm, and even more preferably 45 to 64 mm. The other fibers preferably have a fiber length approximately equivalent to that of the polyimide fibers. This improves spinnability, enhances yarn properties such as strength, and further enhances the physical properties of the flame-retardant fabric. More preferably, all fibers forming the staple yarn have a fiber length approximately equivalent to that of the polyimide fibers.

[0044] In the flame-retardant fabric, the single fiber fineness of the acrylic fiber, the flame-retardant rayon fiber, the lyocell fiber, and the other fibers is preferably 1 to 20 dtex, more preferably 1.5 to 15 dtex, from the viewpoint of strength.

[0045] The flame retardant fabric is not particularly limited, but from the viewpoint of softness and touch, the weight per unit area is preferably 100 to 500 g / m 2 , more preferably 130 to 480 g / m 2 , more preferably 150 to 460 g / m 2 .

[0046] The form of the flame-retardant fabric is not particularly limited; examples include woven and knitted fabrics. From the perspectives of durability and flame retardancy, woven fabrics are preferred. The weave of the fabric is not particularly limited; it may be a plain weave, twill, or satin weave, or a fancy weave using a special loom such as a dobby loom or jacquard loom.

[0047] The flame-retardant fabric exhibits excellent flame retardancy, with a char length of 50 mm or less as measured in a flammability test according to GB / T 5455-1997. A char length of 50 mm or less satisfies the Class A char length standard for "flame-retardant protective clothing" specified in GB8965.1-2009. Preferably, the flame-retardant fabric exhibits a char length of 50 mm or less as measured in a flammability test according to GB / T 5455-1997 after being washed 50 times in accordance with GB / T 17596-1998.

[0048] Furthermore, the flame-retardant fabric exhibits excellent flame retardancy, with an afterglow time of preferably 2.0 seconds or less as measured by a flammability test according to GB / T 5455-1997. More preferably, after 50 washes according to GB / T 17596-1998, the afterglow time is 2.0 seconds or less. An afterglow time of 2.0 seconds or less satisfies the Class A or B afterglow time standards for "flame-retardant protective clothing" specified in GB 8965.1-2009. The flame-retardant fabric more preferably exhibits a char length of 50 mm or less and an afterglow time of 2.0 seconds or less, and particularly preferably exhibits a char length of 50 mm or less and an afterglow time of 2.0 seconds or less after 50 washes according to GB / T 17596-1998.

[0049] Furthermore, the flame-retardant fabric exhibits excellent flame retardancy, with an afterflame time of preferably 2.0 seconds or less as measured by a flammability test according to GB / T 5455-1997. More preferably, the afterflame time is 2.0 seconds or less as measured by a flammability test according to GB / T 17596-1998 after 50 washes. An afterflame time of 2.0 seconds or less satisfies the Class A or B afterflame time standard for "flame-retardant protective clothing" as specified in GB8965.1-2009.

[0050] The flame-retardant fabric of the present invention can be suitably used as a fabric for protective clothing that requires flame retardancy, and protective clothing with excellent flame retardancy using the flame-retardant fabric can be provided inexpensively. The protective clothing of the present invention can be made using the flame-retardant fabric using a known sewing method. Since the flame-retardant fabric has excellent flame retardancy, the protective clothing of the present invention also has excellent flame retardancy. In addition, the flame-retardant fabric has excellent flame retardancy even after repeated washing, so the protective clothing can maintain its flame retardancy even after repeated washing. The protective clothing of the present invention can be used as protective clothing for all operations that require flame retardancy. For example, although there are no particular limitations, it can be used as protective clothing worn at work sites where fires are likely to occur, such as petroleum, petrochemical, coal mining, electric power, and welding, and as protective clothing worn at work sites where dust explosions are assumed, such as metal processing.

[0051] Example

[0052] Hereinafter, the present invention will be described in detail with reference to Examples, but the present invention is not limited to these Examples.

[0053] In the examples and comparative examples, the following fibers were used.

[0054] <Fiber>

[0055] As acrylic fiber I, an acrylic fiber formed from an acrylic copolymer containing 49.5% by weight of acrylonitrile, 49.5% by weight of vinyl chloride and 1.0% by weight of sodium styrene sulfonate, containing 9.1% by weight of antimony trioxide relative to the total weight of the fiber, was used.

[0056] Acrylic fiber I: fineness 1.7 dtex, fiber length 51 mm

[0057] Flame-retardant rayon fiber: Lenzing FR, manufactured by Lenzing, contains a phosphorus-based flame retardant, has a fineness of 2.2 dtex and a fiber length of 51 mm.

[0058] Lyocell fiber: "Tencel (registered trademark)" manufactured by Lenzing, fineness 1.3 dtex, fiber length 51 mm

[0059] Polyimide fiber I: "ASPI (registered trademark)" manufactured by China Jiangsu Aoshen Hi-Tech Materials Co., LTD., fineness 1.67 dtex, fiber length 51 mm

[0060] Polyimide fiber II: "ASPI (registered trademark)" manufactured by China Jiangsu Aoshen Hi-Tech Materials Co., LTD., fineness 1.67 dtex, fiber length 38 mm

[0061] (Examples 1 to 3, Comparative Examples 1 to 3)

[0062] The acrylic fiber, flame-retardant rayon fiber, lyocell fiber, and polyimide fiber were mixed in the amounts shown in Table 1 below to produce spun yarns having the cotton counts shown in Table 1 below. These spun yarns were used as warp and weft yarns to produce 2 / 1 twill fabrics using conventional manufacturing methods. The weft counts are shown in Table 1 below.

[0063] The flame retardancy of the fabrics obtained in Examples 1 to 3 and Comparative Examples 1 to 3 was measured and evaluated as follows, and the results are shown in Table 1 below.

[0064] (Flame retardancy)

[0065] Flammability tests were conducted in accordance with GB / T 5455-1997 to measure the char length (length of the charred portion), afterflame time, and afterglow time of the fabrics. Furthermore, the flammability tests for the fabrics of Examples 1-3 and Comparative Examples 1-3 were conducted on fabrics that had been washed 50 times in accordance with GB / T 17596-1998.

[0066] Table 1

[0067]

[0068] The results in Table 1 above show that the fabrics of Examples 1 to 3 exhibited char lengths of 50 mm or less as measured in the flammability test according to GB / T 5455-1997, indicating excellent flame retardancy. On the other hand, the fabrics of Comparative Examples 1 to 3, which used polyimide fibers with a fiber length of less than 45 mm, exhibited char lengths exceeding 50 mm as measured in the flammability test according to GB / T 5455-1997, indicating poor flame retardancy.

Claims

1. A flame retardant fabric, characterized in that: The flame retardant fabric contains acrylic fiber, one or more regenerated cellulose fibers selected from flame retardant rayon fiber and lyocell fiber, and polyimide fiber. The flame-retardant fabric contains 44.5 to 79 weight percent of the acrylic fiber, 18 to 48 weight percent of the regenerated cellulose fiber, and 3 to 8 weight percent of the polyimide fiber; The fiber lengths of the polyimide fiber and acrylic fiber are both 45 to 64 mm; The char length measured by the flammability test based on GB / T 5455-1997 is 50 mm or less.

2. The flame-retardant fabric according to claim 1, wherein The fiber length of the at least one regenerated cellulose fiber selected from the group consisting of flame-retardant rayon fiber and lyocell fiber is 45 to 127 mm.

3. The flame-retardant fabric according to claim 1 or 2, wherein The acrylic fiber is formed from an acrylonitrile copolymer containing 35 to 85 weight percent of acrylonitrile, 15 to 65 weight percent of one or more halogen-containing monomers selected from halogen-containing vinyl monomers and halogen-containing vinylidene monomers, and 3 weight percent or less of a vinyl monomer containing a sulfonic acid group.

4. The flame-retardant fabric according to claim 1 or 2, wherein The acrylic fiber contains 3.9 to 20 weight % of an antimony compound.

5. The flame-retardant fabric according to claim 1 or 2, wherein The flame retardant rayon fiber contains a phosphorus-based flame retardant.

6. The flame-retardant fabric according to claim 1 or 2, wherein The flame-retardant fabric contains 44.5 to 79% by weight of the acrylic fiber, 18 to 48% by weight of the regenerated cellulose fiber, and 3 to 7.5% by weight of the polyimide fiber.

7. The flame-retardant fabric according to claim 1 or 2, wherein The regenerated cellulose fiber is lyocell fiber.

8. The flame-retardant fabric according to claim 1 or 2, wherein The acrylic fiber, the regenerated cellulose fiber, and the polyimide fiber all have a fiber length of 45 to 64 mm.

9. The flame-retardant fabric according to claim 3, wherein The acrylonitrile copolymer contains a halogen-containing vinyl monomer, and the regenerated cellulose fiber contains a flame-retardant rayon fiber.

10. The flame-retardant fabric according to claim 1 or 2, wherein The flame retardant fabric is a woven fabric.

11. A protective suit, characterized in that: The flame-retardant fabric according to any one of claims 1 to 10 is used.

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