Woven fabric and textile product

Abstract

To provide a woven fabric and a textile product which are excellent in heat resistance, flame resistance and appearance quality, and are extremely excellent in stretchability.SOLUTION: A woven fabric is obtained by using a composite yarn comprising a spun yarn containing a flame-retardant fiber having a limiting oxygen index of 25 or more measured by JIS K7201 and a yarn composed of a conjugate fiber in which two components are stuck together into a side-by-side type or eccentric sheath / core type. A weight ratio of the yarn composed of the conjugate fiber in the composite yarn is 40 to 60 wt.%. The composite yarn is twisted at a twist coefficient K of 270 to 400. A weight ratio of the flame-retardant fiber is 77 wt.% or more based on a weight of the woven fabric, and a weight ratio of the conjugate fiber is 23 wt.% or less based on the weight of the woven fabric. A basis weight of the woven fabric is 220 g / m2 or more, and a ratio CF / TCF of a cover factor CF in a direction of the composite yarn containing one among the warp and the weft to a total cover factor TCF of the woven fabric is 0.3 or less.SELECTED DRAWING: None

Description

[Technical field]

[0001] The present invention relates to a woven fabric and a textile product which are excellent in heat resistance, flame resistance, and appearance quality, and further, have extremely excellent stretchability. [Background technology]

[0002] Flame-retardant fabrics are used as work clothes worn by people engaged in work that may be exposed to flames, such as firefighters, electric power companies, and chemical companies. Such flame-retardant fabrics are mainly made of flame-retardant fibers such as meta-type wholly aromatic polyamide fibers and para-type wholly aromatic polyamide fibers, and generally tend to have poor elasticity.

[0003] As a countermeasure to this problem, for example, Patent Document 1 proposes a woven fabric that is woven using a composite yarn containing composite fibers in which two components are bonded together in a side-by-side or eccentric core-sheath configuration, and that is imparted with elasticity by heat shrinkage. However, there is a problem that increasing the weight ratio of the composite fiber in order to increase the stretchability of the fabric reduces the flame retardancy of the fabric. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] JP 2014-240532 A Summary of the Invention [Problem to be solved by the invention]

[0005] The present invention has been made in consideration of the above problems, and has as its object to provide a woven fabric and a textile product which are excellent in heat resistance, flame resistance, and appearance quality, and further, are extremely excellent in stretchability. [Means for solving the problem]

[0006] As a result of extensive research to achieve the above object, the inventors have found that by skillfully devising the fibers constituting the fabric, it is possible to obtain woven fabrics and fiber products that are excellent in heat resistance, flame resistance, appearance quality, and also in stretchability, and have completed the present invention through further extensive research. Thus, the present invention provides the following:

[0007] 1. A woven fabric made using a composite yarn including a spun yarn containing a flame-retardant fiber with a limiting oxygen index of 25 or more as measured according to JIS K7201, and a yarn made of a composite fiber in which two components are bonded together in a side-by-side or eccentric core-sheath configuration, In the composite yarn, the weight ratio of the yarn made of the composite fiber is 40 to 60% by weight, and the composite yarn is twisted with a twist coefficient K defined by the following formula of 270 to 400, The weight ratio of the flame-retardant fiber is 77% by weight or more based on the weight of the woven fabric, and the weight ratio of the composite fiber is 23% by weight or less based on the weight of the woven fabric, In woven fabrics, the basis weight is 220 g / m 2 The above-mentioned woven fabric is characterized in that the ratio CF / TCF of the cover factor CF in the direction in which the composite yarn is arranged among the warp and weft yarns and the total cover factor TCF of the woven fabric is 0.3 or less. Twist factor K=T×√D where T is the number of twists (turns / 2.54 cm) and D is the total fineness (dtex) of the composite yarn. 2. The woven fabric according to claim 1, wherein the elongation percentage of the warp and weft threads in the direction in which the composite yarn is arranged is within the range of 20 to 50%. 3. A woven fabric as described in 1 or 2 above, in which the stretch recovery rate in the direction in which the composite yarn is arranged among the warp and weft yarns is 70% or more. 4. A woven fabric according to any one of 1 to 3 above, which has a limiting oxygen index of more than 24 as measured according to JIS K7201. 5. A woven fabric according to any one of 1 to 4 above, which satisfies all of the following requirements (1) to (4). (1) In the flame resistance test specified in ISO 15025 Procedure A, all of the following are satisfied: a) No flame b) No flaming or molten falling objects c) No holes larger than 5 mm d) Residual dust lasts for 2 seconds or less e) Afterflame lasts less than 2 seconds (2) In the flame resistance test specified in ISO 15025 Procedure B, all of the following are satisfied: a) The flame does not reach the edge b) No flaming or molten falling objects c) Residual flash is less than 2 seconds d) Afterflame lasts less than 2 seconds (3) In the flame resistance test specified in ASTM D6413, all of the following are satisfied: a) Char length is 100mm or less b) Afterflame lasts less than 2 seconds c) No melting d) No dripping (4) The tear strength as specified in ISO 13937-2 is 35 N or more. 6. The woven fabric according to any one of 1 to 5 above, wherein the flame-retardant fiber is one or more types of fiber selected from the group consisting of meta-type wholly aromatic polyamide fiber, para-type wholly aromatic polyamide fiber, polyparaphenylene benzoxazole fiber, polybenzimidazole fiber, polyimide fiber, polyetherimide fiber, polyamideimide fiber, carbon fiber, polyphenylene sulfide fiber, polyvinyl chloride fiber, flame-retardant rayon, modacrylic fiber, flame-retardant acrylic fiber, flame-retardant polyester fiber, flame-retardant vinylon fiber, melamine fiber, fluorine fiber, flame-retardant wool, and flame-retardant cotton. 7. The woven fabric according to any one of 1 to 6 above, wherein the yarn made of the conjugated fiber is a multifilament having a single fiber fineness of 0.5 to 10.0 dtex and a total fineness of 20 to 200 dtex. 8. The woven fabric according to any one of 1 to 7 above, wherein at least one of the components constituting the composite fiber is of recycled or plant origin. 9. A textile product made using the fabric described in any one of 1 to 8 above, the textile product being selected from the group consisting of firefighting suits, fire-resistant suits, office uniforms, racing suits for motorsports, work clothes, gloves, hats, vests, seats, tents, membrane materials, hoods, building materials, housing materials, and vehicle interior materials. Effect of the Invention

[0008] According to the present invention, it is possible to obtain woven fabrics and fiber products which are excellent in heat resistance, flame resistance, and appearance quality, as well as in stretchability. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0009] Hereinafter, an embodiment of the present invention will be described in detail. First, in the present invention, the composite yarn includes a spun yarn containing a flame-retardant fiber (hereinafter, sometimes simply referred to as a "flame-retardant fiber") having a limit oxygen index of 25 or more as measured according to JIS K7201, and a yarn made of the composite fiber.

[0010] (Flame-retardant fibers) Examples of flame-retardant fibers include meta-type wholly aromatic polyamide fibers (meta-aramid fibers), para-type wholly aromatic polyamide fibers (para-aramid fibers), polyparaphenylenebenzoxazole fibers, polybenzimidazole fibers, polyimide fibers, polyetherimide fibers, polyamideimide fibers, carbon fibers, polyphenylene sulfide fibers, polyvinyl chloride fibers, flame-retardant rayon, modacrylic fibers, flame-retardant acrylic fibers, flame-retardant polyester fibers, flame-retardant vinylon fibers, melamine fibers, fluorine fibers, flame-retardant wool, and flame-retardant cotton. One or more of these flame-retardant fibers can be used. Among these, meta-type wholly aromatic polyamide fibers and para-type wholly aromatic polyamide fibers are particularly useful because they exhibit an excellent limiting oxygen index and have excellent mechanical properties.

[0011] The metaphenylene isophthalamide fiber is a fiber in which aromatic rings constituting the main skeleton are meta-bonded by amide bonds, and 85 mol% or more of the total repeating units of the polymer are metaphenylene isophthalamide units. In particular, polymetaphenylene isophthalamide homopolymer is preferred. The third component that can be copolymerized at 15 mol% or less (preferably 5 mol% or less) of the total repeating units includes, as diamine components, aromatic diamines such as paraphenylenediamine, 3,4'-diaminodiphenyl ether, 4,4'-diaminodiphenyl ether, paraxylylenediamine, biphenylenediamine, 3,3'-dichlorobenzidine, 3,3'-dimethylbenzidine, 3,4'-diaminodiphenylmethane, 4,4'-diaminodiphenylmethane, and 1,5-naphthalenediamine. Also, as acid components, aromatic dicarboxylic acids such as terephthalic acid, naphthalene-2,6-dicarboxylic acid, and naphthalene-2,7-dicarboxylic acid can be mentioned. In addition, in these aromatic diamines and aromatic dicarboxylic acids, some of the hydrogen atoms in the aromatic ring may be substituted with halogen atoms or alkyl groups such as methyl groups. When 20% or more of the total terminals of the polymer are blocked with a monovalent diamine such as aniline or a monovalent carboxylic acid component, this is preferred because it reduces the decrease in strength of the fiber when it is kept at high temperatures for a long time.

[0012] Such meta-type wholly aromatic polyamides can be produced by known interfacial polymerization methods, and the degree of polymerization of the polymer is preferably such that the intrinsic viscosity (IV) of the polymer measured in an N-methyl-2-pyrrolidone solution having a concentration of 0.5 g / 100 ml is in the range of 1.3 to 1.9 dl / g.

[0013] The meta-type wholly aromatic polyamide may also contain an alkylbenzenesulfonate onium salt. Examples of the alkylbenzenesulfonate onium salt include hexylbenzenesulfonate tetrabutylphosphonium salt, hexylbenzenesulfonate tributylbenzylphosphonium salt, dodecylbenzenesulfonate tetraphenylphosphonium salt, dodecylbenzenesulfonate tributyltetradecylphosphonium salt, dodecylbenzenesulfonate tetrabutylphosphonium salt, and dodecylbenzenesulfonate tributylbenzylammonium salt. Among these, dodecylbenzenesulfonate tetrabutylphosphonium salt or dodecylbenzenesulfonate tributylbenzylammonium salt is preferred because it is easily available, has good thermal stability, and has high solubility in N-methyl-2-pyrrolidone.

[0014] In order to obtain a sufficient effect of improving dyeability, the content of the alkylbenzenesulfonic acid onium salt is preferably 2.5 mol % or more, and more preferably in the range of 3.0 to 7.0 mol %, based on the poly-m-phenyleneisophthalamide.

[0015] The method of mixing poly-m-phenylene isophthalamide and an onium salt of alkylbenzenesulfonic acid may be, for example, a method of mixing and dissolving poly-m-phenylene isophthalamide in a solvent, and then dissolving the onium salt of alkylbenzenesulfonic acid in the solvent. The dope thus obtained is formed into fibers by a known method.

[0016] For the purpose of improving dyeability and resistance to fading, the polymer used for the meta-type wholly aromatic polyamide fiber may have an aromatic diamine component or an aromatic dicarboxylic acid halide component different from the main structural unit of the repeating structure copolymerized as a third component in an aromatic polyamide skeleton containing a repeating structural unit represented by the following formula (1) in an amount of 1 to 10 mol % based on the total amount of the repeating structural units of the aromatic polyamide. -(NH-Ar1-NH-CO-Ar1-CO)-...Formula (1) Ar1 is a divalent aromatic group having a linking group in a meta- or parallel axial direction.

[0017] As the third component, it is possible to copolymerize aromatic diamines or aromatic dicarboxylic acid dichlorides represented by the following formulas (2), (3), (4) and (5). Specific examples of the aromatic diamines shown in formulas (2) and (3) include p-phenylenediamine, chlorophenylenediamine, methylphenylenediamine, acetylphenylenediamine, aminoanisidine, benzidine, bis(aminophenyl)ether, bis(aminophenyl)sulfone, diaminobenzanilide, diaminoazobenzene, etc. Specific examples of the aromatic dicarboxylic acid dichlorides shown in formulas (4) and (5) include terephthalic acid chloride, 1,4-naphthalenedicarboxylic acid chloride, 2,6-naphthalenedicarboxylic acid chloride, 4,4'-biphenyldicarboxylic acid chloride, 5-chloroisophthalic acid chloride, 5-methoxyisophthalic acid chloride, bis(chlorocarbonylphenyl)ether, etc.

[0018] H2N-Ar2-NH2...Formula (2) H2N-Ar2-Y-Ar2-NH2... formula (3) XOC-Ar3-COX...Formula (4) XOC-Ar3-Y-Ar3-COX...Formula (5) Ar2 is a divalent aromatic group different from Ar1, Ar3 is a divalent aromatic group different from Ar1, Y is at least one atom or functional group selected from the group consisting of an oxygen atom, a sulfur atom, and an alkylene group, and X is a halogen atom.

[0019] The degree of crystallinity of the meta-type wholly aromatic polyamide fiber is preferably 5 to 35% in terms of good dye exhaustion and easy adjustment to a target color even with a small amount of dye or weak dyeing conditions, etc. Furthermore, it is more preferably 15 to 25% in terms of preventing uneven distribution of the dye on the surface, high resistance to discoloration, and ensuring dimensional stability required for practical use.

[0020] The amount of residual solvent in the meta-type wholly aromatic polyamide fiber is preferably 1.0% by weight or less (more preferably 0.3% by weight or less) in order not to impair the excellent flame retardant performance of the meta-type wholly aromatic polyamide fiber and in order to prevent uneven distribution of the dye on the surface and to ensure high resistance to discoloration.

[0021] The polymerization method for the meta-type wholly aromatic polyamide polymer may be, for example, the solution polymerization method or interfacial polymerization method described in JP-B-35-14399, US Pat. No. 3,360,595, JP-B-47-10863, etc.

[0022] The spinning solution may be an amide-based solvent containing an aromatic copolyamide polymer obtained by the above-mentioned solution polymerization or interfacial polymerization, or may be a solution obtained by isolating the polymer from the above-mentioned polymerization solution and dissolving it in an amide-based solvent.

[0023] Examples of the amide solvent used in the polymerization include N,N-dimethylformamide, N,N-dimethylacetamide, N-methyl-2-pyrrolidone, dimethylsulfoxide, etc. Among these, N,N-dimethylacetamide is particularly preferred.

[0024] The obtained copolymerized aromatic polyamide polymer solution is preferably stabilized by further containing an alkali metal salt or an alkaline earth metal salt, and can be used at a higher concentration and at a lower temperature. The alkali metal salt or alkaline earth metal salt is preferably 1% by weight or less, more preferably 0.1% by weight or less, based on the total weight of the polymer solution. In the spinning and coagulation step, the spinning solution (meta-type wholly aromatic polyamide polymer solution) obtained above is spun into a coagulation solution and coagulated.

[0025] The spinning device is not particularly limited, and a known wet spinning device can be used. In addition, as long as it can perform stable wet spinning, there is no need to particularly limit the number of spinning holes, the arrangement state, the hole shape, etc. of the spinneret, and for example, a multi-hole spinneret for staple fibers having 1000 to 30000 holes and a spinning hole diameter of 0.05 to 0.2 mm may be used. In addition, the temperature when the spinning solution (meta-type wholly aromatic polyamide polymer solution) obtained above is spun from the spinneret is suitably in the range of 20 to 90°C.

[0026] The coagulation bath used to obtain the fibers is an amide-based solvent that does not substantially contain inorganic salts. In particular, it is preferable to use an aqueous solution with an NMP concentration of 45 to 60% by weight, with the bath temperature in the range of 10 to 50°C. If the concentration of the amide-based solvent (preferably NMP) is less than 45% by weight, the skin will be thick, the washing efficiency in the washing step will decrease, and it may be difficult to reduce the amount of solvent remaining in the fibers. On the other hand, if the concentration of the amide-based solvent (preferably NMP) exceeds 60% by weight, uniform coagulation cannot be performed even to the inside of the fibers, so it is difficult to reduce the amount of solvent remaining in the fibers. The immersion time of the fibers in the coagulation bath is suitably in the range of 0.1 to 30 seconds.

[0027] The stretching is carried out in an amide solvent. In particular, it is preferable to carry out the stretching at a ratio of 3 to 4 in a plastic stretching bath in which the concentration of NMP is 45 to 60% by weight and the temperature of the bath is in the range of 10 to 50° C. After stretching, the film is thoroughly washed by passing it through an aqueous solution of NMP having a concentration of 20 to 40% by weight at 10 to 30° C. and then through a warm water bath at 50 to 70° C.

[0028] The washed fibers are subjected to a dry heat treatment at a temperature of 270 to 290° C., whereby meta-type wholly aromatic polyamide fibers that satisfy the above ranges of crystallinity and residual solvent amount can be obtained. By the above-mentioned method, the crystallinity and the amount of remaining solvent can be adjusted to a preferred range.

[0029] The meta-type wholly aromatic polyamide fiber may be a long fiber (multifilament) or a short fiber. When it is mixed with other fibers, the short fiber has a fiber length of 25 to 200 mm, and the single fiber fineness is preferably in the range of 1 to 5 dtex.

[0030] Commercially available metaphenylene isophthalamide fibers include "Conex" (trade name) manufactured by Teijin Limited, "Conex Neo" (trade name) manufactured by Teijin Limited, and "Nomex" (trade name) manufactured by DuPont.

[0031] Next, para-type wholly aromatic polyamide fibers (para-type aramid fibers) are preferably paraphenylene terephthalamide fibers or coparaphenylene-3,4'-oxydiphenylene terephthalamide fibers. Commercially available products include "Twaron" (trade name) manufactured by Teijin Limited, "Kevlar" (trade name) manufactured by Toray DuPont Co., Ltd., and "Technora" (trade name) manufactured by Teijin Limited.

[0032] Furthermore, these fibers may contain additives such as antioxidants, infrared absorbers, ultraviolet absorbers, heat stabilizers, titanium oxide, colorants, inert fine particles, etc., as long as the additives do not impair the object of the present invention. However, it is preferable that the fibers do not contain flame retardants.

[0033] (About composite fibers) The composite fiber is preferably a fiber composed of one component made of polytrimethylene terephthalate, or a composite fiber in which two components are bonded in a side-by-side or eccentric core-sheath manner.Specific examples of the two components include polytrimethylene terephthalate and polytrimethylene terephthalate, polytrimethylene terephthalate and polyethylene terephthalate, polyethylene terephthalate and polyethylene terephthalate, and polyethylene terephthalate and polybutylene terephthalate.

[0034] Here, polytrimethylene terephthalate refers to a fiber made of polyester containing trimethylene terephthalate units as the main repeating units, and refers to fibers containing trimethylene terephthalate units in an amount of 50 mol% or more, preferably 70 mol% or more, more preferably 80 mol% or more, and particularly preferably 90 mol% or more. Accordingly, it contains polytrimethylene terephthalate in which the total amount of other acid components and / or glycol components as the third component is contained in the range of 50 mol% or less, preferably 30 mol% or less, more preferably 20 mol% or less, and particularly preferably 10 mol% or less.

[0035] Polytrimethylene terephthalate is produced by condensing terephthalic acid or a functional derivative thereof with trimethylene glycol or a functional derivative thereof in the presence of a catalyst under suitable reaction conditions.

[0036] The shape of the yarn made of the composite fiber is not particularly limited, and may be a long fiber (multifilament) or a short fiber (spun yarn), but a long fiber (multifilament) is preferable in order to obtain excellent elasticity. In addition, it is preferable that at least one of the components constituting the composite fiber is derived from recycled materials or plants. Examples include recycled polyethylene terephthalate and plant-derived polytrimethylene terephthalate.

[0037] In the yarn made of the composite fiber, the total fineness and single fiber fineness may be appropriately selected depending on the application, and the total fineness is preferably in the range of 20 to 200 dtex and the single fiber fineness is preferably in the range of 0.5 to 10.0 dtex.

[0038] Furthermore, these fibers may contain additives such as antioxidants, infrared absorbers, ultraviolet absorbers, heat stabilizers, titanium oxide, colorants, inert fine particles, etc., as long as the additives do not impair the object of the present invention. However, it is preferable that the fibers do not contain flame retardants.

[0039] (About composite yarn) In the present invention, the composite yarn includes the above-mentioned spun yarn and the yarn made of the above-mentioned composite fiber. In this case, it is important that the weight ratio of the yarn made of the composite fiber contained in the composite yarn is within a range of 40 to 60% by weight (more preferably 45 to 55% by weight) relative to the weight of the composite yarn in order to achieve both flame retardancy and stretchability.

[0040] It is important that the composite yarn is a ply-twisted yarn. More specifically, it is preferable to ply-twist the spun yarn and the composite fiber yarn using a commercially available up-twister, Italian-type twister, double twister, or the like. In this case, it is important to perform twisting so that the twist coefficient K is 270 to 400. Here, the twist coefficient K=T×√D, where T is the number of twists (turns / 2.54 cm) and D is the total fineness (dtex) of the composite yarn. If the twist coefficient is less than 270, unevenness due to shrinkage of the composite fiber appears on the woven surface, which may deteriorate the appearance quality and the anti-pilling properties. Conversely, if it exceeds 400, the thermal shrinkage of the composite yarn may be inhibited, and the elongation rate may be deteriorated.

[0041] The twist setting may be carried out depending on the quality required. The twist setting of the composite yarn (plied yarn) can be performed by vacuum steam setting, which is used for setting normal spun yarn. The temperature at which the composite plied yarn is set is preferably in the range of 50 to 95°C (more preferably 50 to 85°C). If the twist setting temperature of the composite yarn (plied yarn) is too high, the stretchability of the finally obtained fabric may be impaired.

[0042] (About conductive fibers) In addition, it is preferable that the woven fabric of the present invention contains conductive fibers in order to prevent static electricity. In this case, the conductive fibers may be contained in the spun yarn or composite yarn, or may be contained in the woven fabric separately from these.

[0043] The conductive fiber preferably contains at least one of the following conductors in the conductive part: carbon black, metal particles (silver particles, copper particles, aluminum particles, etc.), metal oxides (particles mainly made of titanium oxide, stannic oxide, zinc oxide, indium oxide, etc.), conductive particle-containing polymers containing particles coated with conductive oxides, etc. The form of the conductive fiber may be a structure in which the entire fiber is made of conductive parts, or the non-conductive part and the conductive part may have a cross-sectional shape such as a core-sheath, sandwich, or eccentric shape. The resin forming the conductive part and the non-conductive part is not particularly limited as long as it has fiber-forming properties. Specifically, examples of nylon resins include nylon 6, nylon 11, nylon 12, and nylon 66. Examples of polyester resins include polyethylene terephthalate, polytrimethylene terephthalate, polybutylene terephthalate, polyethylene naphthalate, polycyclohexane terephthalate, and copolymers thereof, and those in which a part of the acid component (terephthalic acid) is replaced with isophthalic acid. Acrylic resins are also acceptable.

[0044] Examples of commercially available conductive fibers include "Metarian" (product name) manufactured by Teijin Limited, "Megana" (product name) manufactured by Unitika Fibers, "Luana" (product name) manufactured by Toray Industries, Inc., "Clacarbo" (product name) manufactured by Kuraray Co., Ltd., "Corebrit ET10" (product name) manufactured by Mitsubishi Chemical Corporation, and "Belltron" (product name) manufactured by KB Seiren Ltd.

[0045] (About the mixture ratio) The woven fabric of the present invention is a woven fabric made using the composite yarn. In order to obtain excellent flame retardancy, it is important that the weight ratio of the flame retardant fiber is 77% by weight or more (preferably 80 to 99% by weight, particularly preferably 85 to 97% by weight) relative to the weight of the woven fabric. It is also important that the weight ratio of the composite fiber is 23% by weight or less (preferably 1 to 20% by weight, particularly preferably 3 to 18% by weight). If the weight ratio of the composite fiber exceeds 23% by weight, the flame retardancy may decrease.

[0046] In the present invention, the composite yarn may be used as the warp and weft of the woven fabric, but it is preferable to use it as either the warp or weft of the woven fabric (preferably the weft) in order to obtain a high stretch rate. In this case, it is important to set the ratio CF / TCF of the cover factor CF (CFweft or CFwarp) in the direction in which the composite yarn is arranged among the warp and weft to the total cover factor TCF of the woven fabric to 0.3 or less (preferably 0.1 to 0.3, particularly preferably 0.18 to 0.28) in order to achieve both high stretchability and flame retardancy. According to the results of the study by the present inventors, since the stretchability of the woven fabric is determined by the total cover factor of the woven fabric, the content of the composite fiber can be reduced while maintaining the stretchability of the woven fabric by changing the balance between CFweft and CFwarp, and as a result, the flame retardancy is improved.

[0047] CFweft = √(weft size dtex) × (weft density / inch) CFwarp = √(warp fineness dtex) × (warp density / inch) TCF = CFweft + CFwarp Note that 1 inch is 2.54 cm.

[0048] The fabric weight is 220g / m 2 or more (more preferably 220 to 300 g / m 2 ) is preferable. 2 Fabrics having a basis weight less than this are not preferred because they have reduced flame retardancy.

[0049] (About textiles) Examples of the weave of the fabric include plain weave, twill weave, and satin weave. In particular, plain weave, 2 / 1 twill, and 2 / 2 twill weave are preferred. Weaves with more floats than this have a high stretch rate, but may have poor anti-pilling properties.

[0050] (Post-processing) Next, the woven fabric is subjected to heat treatments such as scouring, relaxation, dyeing, and setting, so that the yarns made of the composite fibers contained in the woven fabric assume the form of three-dimensional coil crimping, imparting elasticity to the woven fabric. In particular, in the dyeing process, it is preferable to heat the woven fabric to 130°C in a jet dyeing machine and circulate the fabric, as this shrinks the woven fabric in the width direction and imparts high elasticity.

[0051] In dyeing, meta-type wholly aromatic polyamide fibers may be dyed using a cationic dye in combination with an organic solvent acting as a carrier, and if the composite fiber is polyester, it may be dyed using a disperse dye.

[0052] Such woven fabrics may be additionally subjected to various types of processing, such as water absorption processing, water repellency processing, nap raising processing, flame retardancy processing, ultraviolet shielding processing, or processing to impart functions such as antibacterial agents, deodorant agents, insect repellents, phosphorescent agents, retroreflective agents, and negative ion generating agents.

[0053] (About the effect) The thus obtained woven fabric has the above-mentioned structure, and therefore has not only flame retardancy but also excellent elasticity and appearance quality. In this case, the above-mentioned composite yarn is preferably used as the weft yarn. In particular, it is preferable that the entire amount of the composite yarn is used as the weft yarn. Also, it is preferable that the above-mentioned spun yarn is used as the warp yarn.

[0054] Here, the stretchability of the woven fabric is preferably such that the elongation rate of the warp and weft in the direction in which the composite yarn is arranged (preferably the weft direction) is within the range of 20 to 50%. Also, the elongation recovery rate of the woven fabric is preferably such that the elongation recovery rate of the warp and weft in the direction in which the composite yarn is arranged (preferably the weft direction) is 70% or more (more preferably 73 to 99%). Also, the flame retardancy of the woven fabric is preferably such that the limit oxygen index of the woven fabric measured according to JIS K7201 exceeds 24 (more preferably 24.5 or more).

[0055] The woven fabric of the present invention can have high elongation and at the same time excellent flame retardancy. In particular, in a flame resistance test method in which ignition starts from the bottom, i.e., in ISO 15025 Procedure A, the flame does not reach the edge, there is no flame / melt falling, afterglow is 2 seconds or less, and afterglow is 2 seconds or less; in ISO 15025 procedure B, the flame does not reach the edge, there is no flame / melt falling, afterglow is 2 seconds or less, and afterglow is 2 seconds or less; and in ASTM D6413, the char length is 100 mm or less, afterglow is 2 seconds or less, no melting, and no dripping. In addition, it is preferable that the tear strength as described in ISO 13937-2 is 35 N or more (more preferably 35 to 70 N) in both the warp and weft directions.

[0056] Next, the textile product of the present invention is made using the above-mentioned woven fabric. Since the textile product uses the above-mentioned woven fabric, it has not only flame retardancy but also excellent elasticity and appearance quality. Such textile products include firefighting suits, fireproof suits, office uniforms, racing suits for motorsports, work clothes, gloves, hats, vests, various industrial materials (sheets, tents, membrane materials, hoods, building materials, housing materials, vehicle interior materials, etc.), etc. Furthermore, the work clothes include work clothes for ironworks and steel factories, work clothes for welding work, work clothes in explosion-proof areas, etc. Furthermore, the gloves include work gloves used in the aircraft industry, information equipment industry, precision equipment industry, etc. that handle precision parts. EXAMPLES

[0057] Examples and Comparative Examples of the present invention will now be described in detail, but the present invention is not limited thereto. The measurement items in the examples were measured by the following methods. (1) LOI (Limit Oxygen Index) The limiting oxygen index (LOI) was measured according to JIS K7201:1999 (combustion test method for polymeric materials using the oxygen index method). (2) Flame resistance test Measured according to ISO 15025 procedure A, ISO 15025 procedure B and ASTM D6413. (3)Stretchability The elongation rate and elongation recovery rate were measured according to JIS L1096-2010 (Method B, constant load method). (4) Appearance quality The sunlight was directed from a north window at an angle of approximately 45 degrees onto the surface of the fabric, and the appearance was judged on a two-level scale of "good" or "poor" when viewed perpendicular to the surface of the fabric. (5) Fineness Measured according to JIS L1013-2010 correct fineness.

[0058] [Spun Yarn 1] In the spinning process, short fibers made of polymetaphenylene isophthalamide fiber (Teijin Limited's "Conex Neo" (product name)) with a single fiber fineness of 1.7 dtex, cut length (fiber length) of 51 mm, and LOI of 26, polyparaphenylene terephthalamide (PPTA) fiber (Teijin Limited's "Twaron" (product name)) with a single fiber fineness of 1.7 dtex, cut length (fiber length) of 51 mm, and limit oxygen index of 25 as specified in E-2 of JIS1091:1999, and short fibers made of conductive fiber (Mitsubishi Chemical Corporation's "Corebrit ET10" (product name)) with a single fiber fineness of 3.3 dtex and cut length (fiber length) of 38 mm were mixed in the weight ratio of 93:5:2 in this order, and a first twist was applied in the Z direction with a twist number of 24 times / 2.54 cm (twist coefficient = 292) to obtain a single yarn of 40 British cotton count. Table 1 shows the results.

[0059] [Spun Yarn 2] In the spinning process, short fibers made of polymetaphenylene isophthalamide fiber (Teijin Limited's "Conex Neo" (product name)) with a single fiber fineness of 1.7 dtex, cut length (fiber length) of 51 mm, and LOI of 26, polyparaphenylene terephthalamide (PPTA) fiber (Teijin Limited's "Twaron" (product name)) with a single fiber fineness of 1.7 dtex, cut length (fiber length) of 51 mm, and limit oxygen index of 25 as specified in E-2 of JIS1091:1999, and short fibers made of conductive fiber (Mitsubishi Chemical Corporation's "Corebrit ET10" (product name)) with a single fiber fineness of 3.3 dtex and cut length (fiber length) of 38 mm were mixed in the weight ratio of 93:5:2 in this order, and a first twist was applied in the Z direction with a twist number of 21 times / 2.54 cm (twist coefficient = 295) to obtain a single yarn of 30 British cotton count. Table 1 shows the results.

[0060] [Composite fiber 1] A polyester-based elastic fiber (Teijin Frontier's Solotex EcoHybrid (product name), a composite fiber in which a polytrimethylene terephthalate component and a polyethylene terephthalate component are bonded side-by-side) with a total fineness of 167 dtex / 72 strands was used. Table 2 shows the results.

[0061] [Composite fiber 2] A polyester-based elastic fiber (Teijin Frontier's Solotex EcoHybrid (product name), a composite fiber in which a polytrimethylene terephthalate component and a polyethylene terephthalate component are bonded side-by-side) with a total fineness of 84 dtex / 36 strands was used. Table 2 shows the results.

[0062] [Example 1] Warp yarn: Two spun yarns 1 were combined and twisted in the S direction using a double twister with 24 twists / 2.54 cm, and then the twist was set using a vacuum steam setting machine at a setting temperature of 90°C for a setting time of 30 minutes. Weft yarn: Two strands of spun yarn 1 and composite fiber 1 were combined and twisted in the S direction using a double twister with 20 twists / 2.54 cm. The twist was then set using a vacuum steam setting machine at a setting temperature of 70°C for a setting time of 20 minutes.

[0063] Next, the warp and weft yarns were used to weave a 2 / 1 twill weave with a fabric density of 85 warp threads / 2.54 cm and 35 weft threads / 2.54 cm. The woven fabric was then set by the usual method of singeing, scouring, and spreading (temperature 160°C x time 30 seconds), and then dyed with a fully aromatic polyamide fiber dyeing solution (liquor ratio 1:20) containing 16% owf cationic dye (BASF: Basacry Red GL), 10 g / L carrier agent, 3 g / L acetic acid, 20 g / L sodium nitrate, and 1 g / L dispersant (Meisei Chemical: Disper VG) in a liquid flow dyeing machine at a temperature of 130°C for 60 minutes.

[0064] Next, the fabric was heated from room temperature to 130°C for 30 minutes in a liquid flow dyeing machine with disperse dye (Kayalon Polyester Blue GL-SF) 6% owf, acetic acid 5g / L, sodium acetate 20g / L, sodium nitrate 25g / L, and dispersant (Meisei Chemical: Disper VG) 1g / L. After dyeing, reduction washing was performed, the fabric was dried, and the fabric was set at the same width (temperature 180°C x time 30 seconds). The evaluation results are shown in Tables 3 to 5.

[0065] [Examples 2 and 3, Comparative Examples 1 to 8] Examples 2 and 3 and Comparative Examples 1 to 8 were the same as Example 1 except that the yarn type and twist coefficient were changed. The evaluation results are shown in Tables 3 to 5.

[0066] [Table 1]

[0067] [Table 2]

[0068] [Table 3]

[0069] [Table 4]

[0070] [Table 5] [Industrial Applicability]

[0071] INDUSTRIAL APPLICABILITY According to the present invention, there are provided a woven fabric which is dyeable and flame retardant as well as having excellent elasticity and good appearance quality, and a textile product using said woven fabric, and the industrial value of this invention is extremely great.

Claims

1. A woven fabric using a composite yarn including a spun yarn containing a flame-retardant fiber having a limiting oxygen index of 25 or more as measured according to JIS K7201, and a yarn made of a composite fiber in which two components are bonded together in a side-by-side or eccentric core-sheath configuration, In the composite yarn, the weight ratio of the yarn made of the composite fiber is 40 to 60% by weight, and the composite yarn is twisted at a twist coefficient K defined by the following formula of 270 to 400, The weight ratio of the flame-retardant fiber is 77% by weight or more based on the weight of the woven fabric, and the weight ratio of the composite fiber is 23% by weight or less based on the weight of the woven fabric, In the case of woven fabric, the basis weight is 220 g / m ２ and wherein the ratio CF / TCF of the cover factor CF in the direction in which the composite yarn is arranged among the warp and weft yarns and the total cover factor TCF of the woven fabric is 0.3 or less. Twist factor K = T x √D where T is the number of twists (turns / 2.54 cm) and D is the total fineness (dtex) of the composite yarn.

2. The woven fabric according to claim 1, wherein the elongation percentage of the warp and weft in the direction in which the composite yarn is arranged is within a range of 20 to 50%.

3. 2. The woven fabric according to claim 1, wherein the stretch recovery rate in the direction in which the composite yarn is arranged among the warp yarns and the weft yarns is 70% or more.

4. 2. The woven fabric according to claim 1, which has a limit oxygen index of more than 24 as measured in accordance with JIS K7201.

5. The woven fabric according to claim 1, which satisfies all of the following requirements (1) to (4): (1) In the flame resistance test specified in ISO 15025 Procedure A, all of the following are satisfied: a) No flame b) No flaming or molten falling objects c) No holes larger than 5 mm d) Residual light lasts for 2 seconds or less e) Afterflame lasts less than 2 seconds (2) In the flame resistance test specified in ISO 15025 Procedure B, all of the following are satisfied: a) The flame does not reach the edge b) No flaming or molten falling objects c) Residual light lasts for 2 seconds or less d) Afterflame lasts less than 2 seconds (3) In the flame resistance test specified in ASTM D6413, all of the following are satisfied: a) Carbonization length 100mm or less b) Afterflame lasts for 2 seconds or less c) No melting d) No dripping (4) The tear strength as defined in ISO 13937-2 is 35 N or more.

6. 2. The woven fabric according to claim 1, wherein the flame-retardant fiber is one or more types of fiber selected from the group consisting of meta-type wholly aromatic polyamide fiber, para-type wholly aromatic polyamide fiber, polyparaphenylene benzoxazole fiber, polybenzimidazole fiber, polyimide fiber, polyetherimide fiber, polyamideimide fiber, carbon fiber, polyphenylene sulfide fiber, polyvinyl chloride fiber, flame-retardant rayon, modacrylic fiber, flame-retardant acrylic fiber, flame-retardant polyester fiber, flame-retardant vinylon fiber, melamine fiber, fluorine fiber, flame-retardant wool, and flame-retardant cotton.

7. 2. The woven fabric according to claim 1, wherein the yarn made of the composite fiber is a multifilament having a single fiber fineness of 0.5 to 10.0 dtex and a total fineness of 20 to 200 dtex.

8. The woven fabric according to claim 1 , wherein at least one of the components constituting the composite fiber is of recycled or plant origin.

9. A textile product made using the woven fabric according to any one of claims 1 to 8, the textile product being selected from the group consisting of firefighting suits, fire-resistant suits, office uniforms, racing suits for motorsports, work clothes, gloves, hats, vests, seats, tents, membrane materials, hoods, building materials, housing materials, and vehicle interior materials.

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