Fabric with flame-retardant and three-proofing functions as well as preparation method and application of fabric

Abstract

The invention discloses a fabric with flame-retardant and three-proofing functions and a preparation method thereof, and belongs to the field of textiles. According to the fabric, flame-retardant yarns spun from pre-oxidized polyacrylonitrile fibers are used as a base material and are woven into gray fabric through a tatting process; and then, carrying out after-finishing on the woven fabric through a padding process by adopting a three-proofing assistant working solution with a specific ratio. By selecting the intrinsic flame-retardant fiber material, the adverse effect of flame-retardant after-treatment on the hand feeling of the fabric is fundamentally avoided, and the technical problem that the fabric cannot have two functions at the same time due to the fact that a flame-retardant aid and a three-proofing aid cannot be compatible in a traditional process is successfully solved. The prepared fabric is excellent in flame retardance (the damaged length is smaller than or equal to 50 mm, and afterflame and smoldering are avoided) and has good waterproof, oil-proof and easy-to-clean performance, meanwhile, the original hand feeling of the fabric is kept to the maximum extent, and the fabric is particularly suitable for being used in hotels and other scenes with high-standard requirements for mattress safety and sanitation.

Description

Technical Field

[0001] This invention belongs to the field of textiles, and specifically relates to a fabric with flame retardant and three-proof functions, its preparation method and application. Background Technology

[0002] Flame retardancy in mattresses is a functional requirement with a broad application market, especially in the hotel furniture industry. Mattress flame retardancy must meet relevant national standards. Current flame retardant technologies primarily achieve this by making the mattress materials flame retardant, thereby making the finished mattress flame retardant. Examples include using flame retardant fabrics, flame retardant foam, flame retardant non-adhesive wadding, and flame retardant sewing threads to meet the flame retardant requirements.

[0003] Fabric, as the surface material of a mattress, is key to achieving flame retardancy. Traditional flame retardancy of fabrics is achieved through post-treatment technology that attaches flame retardant additives to the fabric. However, due to the chemical properties of these additives, the feel of the treated fabric can deteriorate. Meanwhile, in addition to the necessary flame retardancy, hotel mattress fabrics also require three-proof properties (waterproof, oil-proof, and stain-proof). Current mattress fabrics also achieve these three-proof functions through post-treatment technology, which involves attaching these additives to the fabric surface.

[0004] Currently, flame retardants and three-proof additives cannot be used in combination due to their chemical composition characteristics. Some durable flame retardants are hydrophilic or polar, requiring a chemical reaction or strong bond with fiber molecules to achieve a flame-retardant effect. Their flame-retardant mechanism usually involves heat absorption, dehydration, and carbon layer formation. Traditional high-efficiency three-proof additives (fluorocarbons) are hydrophobic and oleophobic, forming a low surface energy molecular film on the fiber surface through finishing processes.

[0005] The following are the problems that arise from the current application of flame retardant additives and three-proof additives to fabrics: 1. Apply three-proof finishing first, then flame-retardant finishing. Low surface energy molecular film will hinder the impregnation and penetration of flame-retardant working fluid, resulting in extremely poor or uneven flame-retardant effect. 2. Applying flame-retardant finishing before applying three-proof finishing can leave flame-retardant residue on or inside the fiber surface, disrupting the formation of the low surface energy film of the fluorocarbon three-proof agent. This leads to a significant decrease or even complete failure of the three-proof effect (especially oil repellency). Furthermore, the hygroscopic properties of the flame-retardant also hinder water repellency.

[0006] Therefore, it is impossible to achieve both flame retardancy and three-proof functions on the fabric through fabric finishing processes. It is necessary to develop a fabric that has both flame retardancy and three-proof functions. Summary of the Invention

[0007] To address the issue that flame retardancy and three-proof (waterproof, dustproof, and shockproof) functions cannot be simultaneously achieved on fabrics through finishing processes, this application provides a fabric with both flame retardant and three-proof functions, applicable to various scenarios such as clothing and furniture. This application does not rely on flame retardants, but combines flame-retardant fibers with finishing processes to achieve both functions and a relatively ideal tactile feel.

[0008] A method for preparing a fabric with flame retardant and three-proof functions, comprising the following steps: Step 1: Spin flame-retardant fibers into flame-retardant yarn through a spinning process; the flame-retardant yarn includes polyacrylonitrile fibers. Step 2: Thread the flame-retardant yarn through heddles and reeds, put it on the loom, and set the warp and weft densities to weave it into a grey fabric; Step 3: Prepare the three-proof working solution, impregnate the fabric with the three-proof working solution, and then dry and set it.

[0009] This application uses flame-retardant fibers and does not rely on flame retardants to achieve flame-retardant function. After the three-proof treatment with three-proof additives, it will not weaken the feel of the fabric, achieving the coexistence of flame retardant and three-proof functions and ensuring that the fabric has a relatively ideal feel.

[0010] Polyacrylonitrile fiber is an intermediate product in the production process of polyacrylonitrile (PAN)-based carbon fiber. It is made from PAN precursor fibers through pre-oxidation treatment (200-300℃ air environment). It has self-extinguishing properties, heat resistance and chemical stability, and inherently possesses permanent flame retardant function.

[0011] Furthermore, in step 2, the flame-retardant yarn is woven into the greige fabric using a woven process. The pre-oxidation treatment reduces the tensile strength of the polyacrylonitrile fibers, making it difficult to manufacture the greige fabric using a knitting process; therefore, a woven process is chosen to produce the greige fabric.

[0012] Furthermore, in step 2, the flame-retardant fibers are spun into flame-retardant yarn through a spinning process. This yarn is then woven using heddles, reeds, and looms, with warp and weft densities set, to create a fabric with an air-layer structure, thus transforming the flame-retardant yarn into a raw fabric. This air-layer structure fabric, used as mattress material, possesses a full and soft characteristic.

[0013] Furthermore, the fabric weight ranges from 200-600g / m², and it is used as mattress fabric.

[0014] Further, step 3 includes: Step 3.1: Dilute the three-proof additive with water and stir evenly to prepare the three-proof working solution; Step 3.2: Immerse the billet in the three-proof working solution and squeeze it through the pressure rollers; Step 3.3: Dry the treated fabric at a temperature of ≥155℃.

[0015] Furthermore, in step 3.1, the water content in the three-proof working fluid is 86-93% by mass.

[0016] Water and oil repellent auxiliaries include fluorinated and fluorine-free auxiliaries. Specifically, fluorinated auxiliaries include: ① Fluorocarbon copolymers: polymers formed by copolymerization of fluorinated monomers with hydrocarbons or other fluorinated monomers. This structure achieves water and oil repellency by reducing surface energy. The properties of copolymers can be adjusted through copolymerization modification, such as improving wash resistance or hand feel; ② Organic fluorine resins: these are thermoplastic resins containing fluorine atoms in their molecules, such as polytetrafluoroethylene (PTFE) and polyvinylidene fluoride (PVDF). They rely on low surface energy to provide weather resistance, chemical resistance, and self-cleaning properties. The resins themselves are stable and can remain stable at extreme temperatures. Fluorine-free auxiliaries, one type of which mainly consists of hydrocarbons, are organic compounds composed only of carbon and hydrogen elements. They achieve water repellency by reducing the surface energy of fabrics, but usually need to be compounded with acrylates to improve oil, stain, and wash resistance. Their advantages are environmental friendliness and low cost, but their performance is limited when used alone.

[0017] Furthermore, in step 3.2, the working parameters are set as follows: roll pressure 3.3-3.7 bar, speed not greater than 10 m / min, and liquid carryover rate controlled at 80%±5%.

[0018] Furthermore, in step 3.3, the treated fabric is introduced into a continuous hot air dryer and shaped at a temperature of ≥155℃ and a speed of no more than 10m / min.

[0019] Temperature is a crucial parameter; it must be ≥155℃ and kept in the oven for at least 3 minutes to achieve the desired combination of the two functions in the fabric made from the fiber component selected in this patent.

[0020] The aforementioned fabric is both flame-retardant and three-proof. It can be used directly on the surface of a mattress and then sewn together with other layers of the mattress (such as sponge or non-adhesive cotton) to form a complete mattress product.

[0021] As a second inventive point, a fabric obtained by the above-mentioned preparation method of a fabric with flame-retardant and three-proof functions is provided.

[0022] As the third invention, the application of the aforementioned fabric in home furnishings.

[0023] The beneficial effects of this invention include: 1) Achieve both flame retardancy and three-proof functions in mattress fabric to meet the high standards required by industries such as hotels for mattresses.

[0024] 2) Because special polyacrylonitrile fiber is used as the flame-retardant fiber, the use of flame-retardant additives in the finishing process is avoided, which significantly improves the feel of the fabric and makes it soft and comfortable.

[0025] 3) Flame-retardant fibers have excellent heat resistance and chemical stability, resulting in durable fabrics with long-lasting functionality.

[0026] 4) The production process is simple, easy to scale up, and the cost is controllable. Attached Figure Description

[0027] Figure 1 This is a flowchart of the preparation method of this application. Detailed Implementation

[0028] The technical solutions of the embodiments of the present invention will be explained and described below. However, the following embodiments are only preferred embodiments of the present invention and not all of them. Other embodiments obtained by those skilled in the art based on the embodiments in the implementation methods without creative effort are all within the protection scope of the present invention.

[0029] The following table shows the information on the adjuvants used in the examples:

[0030] Additive suppliers include: Transfar's TF series; Chemours' Teflon™ Protective Fabric Finish (such as Teflon EcoElite™); Huntsman's PHOBOL® (mainly fluorocarbon) and ZELAN™ (fluorine-free / environmentally friendly series is one of its key directions); Rudolf's RUCO-GUARD® (fluorocarbon) is its core three-proof brand; 3M's Scotchgard™ Protector; and Dermatech's DM- series.

[0031] The following models were used in this embodiment: Additive A: TF-5003A; Additive B: TF-569G; Additive C: TF-5008; Additive D: XF-5003; Additive E: TF-501A.

[0032] Example 1 This embodiment provides a method for preparing a fabric with flame-retardant and three-proof functions, such as... Figure 1 As shown, the specific steps are as follows: (1) Fabric weaving: Flame-retardant fibers are spun into flame-retardant yarns through a spinning process; the flame-retardant yarns include polyacrylonitrile fibers; the flame-retardant yarns are used to manufacture greige fabrics through a weaving process; (2) Preparation of working solution: a three-proof auxiliary agent working solution is prepared according to the mass percentage of 5% auxiliary agent C, 2% auxiliary agent B, and the remainder being water; (3) Padding treatment: the fabric sample is placed in the padding equipment, and the working parameters are set as follows: roller pressure 3.5 bar, machine speed 10 m / min, and the liquid carrying rate is controlled at 80%±5%; (4) Baking and setting: the padded fabric is introduced into a continuous hot air dryer with a length of 30m, and the setting is completed at a baking temperature of 160℃ and a machine speed of 10m / min.

[0033] Example 2 This embodiment provides a method for preparing a fabric with flame retardant and three-proof functions. The specific implementation steps are the same as in Embodiment 1, except that the three-proof auxiliary agent working solution is prepared by mixing 8% auxiliary agent C, 4% auxiliary agent E, 2% auxiliary agent B and the remainder being water by mass percentage, and the setting is completed at a baking temperature of 155°C.

[0034] Example 3 This embodiment provides a method for preparing a fabric with flame retardant and three-proof functions. The specific implementation steps are the same as in Embodiment 1, except that the working solution of the three-proof auxiliary agent is prepared by mixing 5% auxiliary agent D, 4% auxiliary agent E, 2% auxiliary agent B and the remainder being water by mass percentage.

[0035] Example 4 This embodiment provides a method for preparing a fabric with flame retardant and three-proof functions. The specific implementation steps are the same as in Embodiment 1, except that the working solution of the three-proof auxiliary agent is prepared by mixing 8% auxiliary agent D, 4% auxiliary agent E, 2% auxiliary agent B and the remainder being water by mass percentage.

[0036] Example 5 This embodiment provides a method for preparing a fabric with flame retardant and three-proof functions. The specific implementation steps are the same as in Embodiment 1, except that the three-proof auxiliary agent working solution is prepared by mixing 8% auxiliary agent A, 2% auxiliary agent B and the remainder water by mass percentage, and the setting is completed at a baking temperature of 170°C.

[0037] Example 6 This embodiment provides a method for preparing a fabric with flame retardant and three-proof functions. The specific implementation steps are the same as in Embodiment 1, except that the three-proof auxiliary agent working solution is prepared by mixing 8% auxiliary agent A, 2% auxiliary agent B and the remainder water by mass percentage, and the setting is completed at a baking temperature of 180°C.

[0038] Comparative Example 1 The specific implementation steps of this comparative example are as follows: (1) Fabric weaving: Flame-retardant yarn is used to construct an air layer structure fabric through knitting process, in which only the surface fabric uses flame-retardant yarn; (2) Preparation of working solution: The working solution of the three-proof auxiliary agent is prepared according to the mass percentage of 8% auxiliary agent C, 1.25% auxiliary agent B, and the rest is water; (3) Impregnation treatment: The fabric sample is placed in the impregnation equipment, and the working parameters are set as follows: roller pressure 3.5 bar, machine speed 10 m / min, and the liquid carrying rate is controlled at 80%±5%; (4) Baking and setting: The impregnated fabric is introduced into a continuous hot air dryer with a length of 30m, and the setting is completed at a baking temperature of 145℃ and a machine speed of 10m / min.

[0039] Comparative Example 2 The specific implementation steps of this comparative example are the same as those of comparative example 1, except that flame-retardant yarn is used to manufacture the greige fabric through a weaving process.

[0040] Comparative Example 3 The specific implementation steps of this comparative example are the same as those of comparative example 1. The difference is that flame-retardant yarn is used to manufacture the greige fabric through a weaving process, and the three-proof auxiliary agent working solution is prepared according to the following mass percentages: 5% auxiliary agent C, 4% auxiliary agent E, 2% auxiliary agent B, and the remainder is water. The setting is completed at a baking temperature of 150℃.

[0041] Finished product performance testing: Flame retardancy was tested using GB / T 5455-2014, water resistance using GB / T 4745-2012, stain resistance (wiping method) using FZ / T 01118-2012, and oil resistance using GB / T 19977-2014. The tests showed that the mattress fabric, which uses flame-retardant yarn to achieve flame retardancy and is then finished with a three-proof additive, meets the basic technical requirements for both flame retardancy and three-proof properties. Detailed technical requirements are shown in the table below.

[0042] Test and verification: 1) Testing methods (reference standards): Flame retardant properties GB / T 5455-2014 Determination of vertical damage length, smoldering and afterflame time of textiles; Waterproofing GB / T 4745-2012 Test and evaluation of waterproofing properties of textiles - Water-soaking method; Oil repellency GB / T 19977-2014 Textiles - Oil repellency and hydrocarbon resistance test; FZ / T 01118-2012 Stain Resistance Test and Evaluation of Stain Resistance of Textiles - Ease of Stain Removal 2) The results are shown in the table below:

[0043] The comparison results between the examples and comparative examples show that the flame retardant and three-proof performance of Examples 1-6 are significantly better than those of Comparative Examples 1-3. Comparative Example 1, using a traditional knitting process and only using flame-retardant yarn in the surface layer, has significantly insufficient flame retardant performance, with a longitudinal damage length of up to 300 mm and an afterflame time of up to 99 seconds, failing to meet the technical requirements. In contrast, Examples 1-6, using a woven process and flame-retardant yarn, show a fundamental improvement in flame retardant performance, with damage lengths all controlled within 50 mm, and no afterflame or smoldering, fully complying with the standard specifications. Regarding the three-proof performance, Comparative Examples 2 and 3, after baking and setting at 145℃ and 150℃ respectively, both had oil resistance levels below level 4, failing to meet the standard. Examples 1-6, all baked and set at ≥155℃, achieved oil resistance levels of level 4 or higher, with oil resistance continuously increasing with increasing baking temperature. Furthermore, Examples 1-6, using different ratios of three-proof additives, all met the basic performance requirements. Comprehensive analysis shows that by using a woven process combined with an auxiliary agent system of 8% auxiliary agent A + 2% auxiliary agent B, and performing finishing under process conditions of 180℃, 3.5 bar, and 10 meters / minute, a mattress fabric with excellent flame retardant properties and optimal three-proof effect can be produced.

[0044] The above description is merely a specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Those skilled in the art should understand that the present invention includes, but is not limited to, the content described in the above specific embodiments. Any modifications that do not depart from the functional and structural principles of the present invention will be included within the scope of the claims.

Claims

1. A method for preparing a fabric with flame-retardant and three-proof functions, characterized in that the steps include... include: Step 1: Spin flame-retardant fibers into flame-retardant yarn through a spinning process; the flame-retardant yarn includes polyacrylonitrile fibers. Step 2: Weave the flame-retardant yarn into a greige fabric; Step 3: Prepare the three-proof working solution, impregnate the fabric with the three-proof working solution, and then dry and set it.

2. The method for preparing a fabric with flame-retardant and three-proof functions according to claim 1, characterized in that, In step 2, the flame-retardant yarn is woven into a fabric using a woven method.

3. The method for preparing a fabric with flame-retardant and three-proof functions according to claim 2, characterized in that, In step 2, flame-retardant fibers are spun into flame-retardant yarn through a spinning process. The yarn is then threaded through heddles, reeds, and onto a loom, with warp and weft densities set, to create a fabric with an air layer structure, thus turning the flame-retardant yarn into a greige fabric.

4. The method for preparing a fabric with flame-retardant and three-proof functions according to claim 3, characterized in that, The fabric weight ranges from 200 to 600 g / m².

5. The method for preparing a fabric with flame-retardant and three-proof functions according to claim 1, characterized in that, Step 3 includes: Step 3.1: Dilute the three-proof additive with water and stir evenly to prepare the three-proof working solution; Step 3.2: Immerse the billet in the three-proof working solution and squeeze it through the pressure rollers; Step 3.3: Dry the treated fabric at a temperature of ≥155℃.

6. The method for preparing a fabric with flame-retardant and three-proof functions according to claim 5, characterized in that, In step 3.1, the water content in the three-proof working fluid is 86-93% by mass.

7. The method for preparing a fabric with flame-retardant and three-proof functions according to claim 5, characterized in that, In step 3.2, the working parameters are set as follows: roll pressure 3.3-3.7 bar, speed not greater than 10 m / min, and liquid carryover rate controlled at 80%±5%.

8. The method for preparing a fabric with flame-retardant and three-proof functions according to claim 5, characterized in that, In step 3.3, the treated fabric is introduced into a continuous hot air dryer and set at a temperature of ≥155℃ and a speed of no more than 10m / min.

9. A fabric obtained by the preparation method of the fabric with flame retardant and three-proof functions as described in any one of claims 1 to 8.

10. The application of the fabric of claim 9 in home furnishings.

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