Woven fabric and textile product

Abstract

To provide a woven fabric having not only excellent stretchability but also sufficient flame retardancy and excellent anti-pilling property, and to provide a textile product using the woven fabric.SOLUTION: A woven fabric contains a composite yarn containing: a spun yarn containing a meta-type wholly aromatic polyamide fiber containing a flame retardant as a flame retardant fiber; and a yarn composed of a flame retardant containing conjugate fiber formed by laminating two components into a side-by-side type or an eccentric core-sheath type.SELECTED DRAWING: None

Description

[Technical field]

[0001] The present invention relates to a woven fabric having not only excellent stretchability but also sufficient flame retardancy and excellent anti-pilling properties, and a textile product using said woven fabric. [Background technology]

[0002] Conventionally, flame-retardant fabrics have been 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. These flame-retardant fabrics mainly use flame-retardant fibers such as meta-type wholly aromatic polyamide fibers and para-type wholly aromatic polyamide fibers, and it is generally considered difficult to impart elasticity to such fabrics.

[0003] In order to impart elasticity to fabrics using flame-retardant fibers, methods such as using elastic yarns (see, for example, Patent Documents 1 to 3) and methods of twisting flame-retardant fibers and then heat-setting and untwisting them (see, for example, Patent Documents 4 to 6) have been proposed. Furthermore, fabrics using elastic yarns have problems such as a rapid loss of stretchability during normal use and washing due to low heat resistance, flame retardancy, and chemical resistance, particularly chlorine resistance.

[0004] In order to solve the above problems, a method has been proposed in which a woven fabric is provided using a composite yarn that includes a spun yarn containing a flame-retardant fiber 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 (e.g., Patent Document 7). However, in order to obtain a high elongation rate, the blending ratio of the composite fiber in the entire woven fabric must be increased, which poses the problem that sufficient flame retardancy cannot be obtained. [Prior art documents] [Patent documents]

[0005] [Patent Document 1] JP 2003-193314 A [Patent Document 2] JP 2006-124865 A [Patent Document 3] JP 2007-9378 A [Patent Document 4] JP 2001-248027 A [Patent Document 5] JP 2005-307429 A [Patent Document 6] JP 2008-190103 A [Patent Document 7] JP 2014-240532 A Summary of the Invention [Problem to be solved by the invention]

[0006] The present invention has been made in consideration of the above-mentioned background, and an object of the present invention is to provide a woven fabric having not only excellent stretchability but also sufficient flame retardancy and excellent anti-pilling properties, and a textile product using the woven fabric. [Means for solving the problem]

[0007] The present inventors have conducted extensive research to achieve the above object, and as a result have completed the present invention. Thus, the present invention provides the following: 1. A woven fabric comprising a spun yarn containing a meta-type wholly aromatic polyamide fiber containing a flame retardant as a flame-retardant fiber, and a composite yarn containing a flame retardant 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. 2. The woven fabric described in 1 above, wherein the weight ratio of the flame-retardant fiber in the woven fabric is within the range of 65 to 85% by weight of the woven fabric, and the weight ratio of the composite fiber in the range of 15 to 35% by weight of the woven fabric. 3. The woven fabric according to the above 1 or 2, wherein the yarn made of the conjugated fiber is a multifilament yarn having a single fiber fineness of 0.5 to 10.0 dtex and a total fineness of 20 to 200 dtex. 4. The woven fabric according to any one of 1 to 3 above, wherein at least one of the two components constituting the composite fiber is of recycled or plant origin. 5. A woven fabric according to any one of 1 to 4 above, wherein the elongation rate of the warp and weft of the woven fabric in the direction in which the composite yarn is arranged is within the range of 10 to 50%. 6. A woven fabric according to any one of 1 to 5 above, wherein the stretch recovery rate in the direction in which the composite yarn is arranged among the warp and weft yarns of the woven fabric is 70% or more. 7. The fabric weight is 280g / m 2 7. The woven fabric according to any one of 1 to 6 above, which is: 8. A woven fabric according to any one of 1 to 7 above, having an anti-pilling property of grade 4 or higher as measured by JIS L1076-2012 Method A ICI type for 10 hours. 9. The woven fabric according to any one of 1 to 8 above, which has a limiting oxygen index of 28 or more as measured according to JIS K7201. 10. A textile product made using the fabric described in any one of 1 to 9 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, there can be obtained a woven fabric having not only excellent stretchability but also sufficient flame retardancy and excellent anti-pilling properties, and a textile product using said woven fabric. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0009] DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention relates to a spun yarn that contains a flame-retardant fiber having a limit oxygen index of 25 or more as measured according to JIS K7201 (hereinafter, also simply referred to as a "flame-retardant fiber").

[0010] Examples of such 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. However, composite fibers containing flame retardants, which will be described later, are excluded.

[0011] Among these, meta-type wholly aromatic polyamide fibers, i.e., metaphenylene isophthalamide fibers (commercially available products include "Conex" (trade name) manufactured by Teijin Limited and "Nomex" (trade name) manufactured by DuPont) are useful because of their excellent limiting oxygen index and excellent mechanical properties. Furthermore, it is also preferable to mix para-type wholly aromatic polyamide fibers, i.e., paraphenylene terephthalamide fibers (commercially available products include "Twaron" (trade name) manufactured by Teijin Limited and "Kevlar" (trade name) manufactured by Toray DuPont Co., Ltd.) and coparaphenylene-3,4'-oxydiphenylene terephthalamide fibers (commercially available products include "Technora" (trade name) manufactured by Teijin Limited)).

[0012] In the present invention, from the viewpoint of use in clothing applications requiring superior flame retardancy, it is important that the spun yarn contains a meta-type wholly aromatic polyamide fiber containing a flame retardant as a flame retardant fiber. In this case, a phosphorus-based flame retardant is preferred as the flame retardant, and tris(chloropropyl)phosphate described in JP-A-2023-23305 is particularly preferred. The meta-type wholly aromatic polyamide fiber containing such a flame retardant can be produced, for example, by the method described in JP-A-2023-23305.

[0013] The flame-retardant fiber may contain additives such as antioxidants, ultraviolet absorbers, heat stabilizers, flame retardants, titanium oxide, colorants, inert fine particles, etc., within the scope of the object of the present invention. The flame-retardant fiber preferably has a fiber length in the range of 35 to 110 mm. In the spun yarn, the total fineness may be appropriately selected depending on the application, taking into consideration surface appearance, heat resistance, heat protection, stretchability, texture, etc., and it is particularly preferable that the total fineness of the spun yarn is in the range of 58 dtex (equivalent to British cotton count 100 single yarn) to 580 dtex (equivalent to British cotton count 10).

[0014] The single fiber fineness of the spun yarn is preferably in the range of 0.6 to 5.5 dtex from the viewpoint of good spinning processability and use in clothing applications requiring softness. The spun yarn preferably contains the flame-retardant fiber in an amount of 80% by weight or more based on the weight of the spun yarn, and may be mixed with conductive fibers, etc. In particular, the spun yarn preferably contains meta-type wholly aromatic polyamide fiber containing a flame retardant in an amount of 85% by weight or more (more preferably 85 to 99% by weight) based on the weight of the spun yarn.

[0015] In the present invention, the composite fiber is a composite fiber in which two components are bonded together in a side-by-side or eccentric core-sheath configuration. The composite yarn contained in the woven fabric of the present invention contains not only the spun yarn but also a yarn made of such a composite fiber, so that the composite fiber takes the form of a three-dimensional coil crimp in the heat treatment process of the fabric, imparting elasticity to the composite yarn, and as a result, imparting elasticity to the woven fabric.

[0016] Here, examples of the two components forming the composite fiber include combinations of polyester / polyester, polyester / nylon, etc. More specifically, combinations such as polytrimethylene terephthalate / polytrimethylene terephthalate, polytrimethylene terephthalate / polyethylene terephthalate, and polyethylene terephthalate / polyethylene terephthalate are preferred. In this case, it is preferable to make the intrinsic viscosities different from each other. From the viewpoint of use in clothing applications where better flame retardancy is required, it is important to contain a flame retardant. As the flame retardant, a phosphorus-based flame retardant is preferred, and for example, diphenyl monoorthoxenyl phosphate described in Japanese Patent No. 492068 or 9,10-dihydro-9-oxa-10-phosphaphenanthrene 10-oxide derivatives described in Japanese Patent No. 4695279 can be preferably exemplified.

[0017] The flame retardant may be added to the composite fiber at the spinning stage or by flame retardant treatment in a bath. The composite fiber may also contain additives such as antioxidants, ultraviolet absorbers, heat stabilizers, titanium oxide, colorants, and inert fine particles.

[0018] 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.

[0019] In the yarn made of the above-mentioned composite fiber, the total fineness and single fiber fineness are 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.

[0020] In the present invention, the composite yarn contains the above-mentioned spun yarn and the yarn made of the composite fiber. In this case, the weight ratio of the yarn made of the composite fiber contained in the composite yarn is preferably 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.

[0021] It is important that the composite yarn is a double-twisted yarn. More specifically, it is preferable to use the spun yarn and the composite fiber and double-twist them using a commercially available up-twister, Italian-type twister, double twister, or the like.

[0022] Twist setting may be performed depending on the required quality. The composite ply-twisted yarn can be twist-set by vacuum steam setting, which is used for setting normal spun yarn. The temperature at which the composite ply-twisted 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 ply-twisted yarn is too high, the stretchability of the finally obtained fabric may be impaired.

[0023] The woven fabric of the present invention is a woven fabric made using such composite yarn. In this case, in order to obtain excellent flame retardancy, it is preferable that the weight ratio of the flame retardant fiber is 65% by weight or more (preferably in the range of 65 to 85% by weight) relative to the weight of the woven fabric. In particular, it is preferable that the weight ratio of the meta-type wholly aromatic polyamide fiber containing a flame retardant is 65% by weight or more (preferably in the range of 65 to 85% by weight) relative to the weight of the woven fabric. If the weight ratio of the flame retardant fiber is less than 65% by weight, the flame retardancy may decrease. Note that, among such flame retardant fibers, the following composite fibers containing a flame retardant and in which two components are bonded together in a side-by-side type or eccentric core-sheath type are excluded.

[0024] The weight ratio of the composite fiber is preferably within the range of 15 to 35% by weight (more preferably 20 to 30% by weight) relative to the weight of the woven fabric. If the weight ratio of the composite fiber exceeds 35% by weight relative to the weight of the woven fabric, the flame tends to propagate along the composite fiber, which is undesirable, and the fabric tends to burn easily. Conversely, if the weight ratio of the composite fiber is less than 15% by weight, not only will the stretchability of the woven fabric decrease, but pilling may also worsen.

[0025] Examples of the fabric structure include plain weave, twill weave, and satin weave, and preferably 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.

[0026] Next, the woven fabric is subjected to heat treatments such as scouring, relaxation, dyeing, and setting, so that the composite fibers in the woven fabric, in which two components are bonded together in a side-by-side or eccentric core-sheath manner, assume the form of three-dimensional coil crimping, imparting elasticity to the 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 fabric in the width direction and gives it high elasticity. In this case, it is preferable to apply a flame retardant treatment to the woven fabric in the bath as described above.

[0027] Various types of processing may be additionally applied, such as water absorption processing, water repellency processing, nap raising processing, ultraviolet shielding, or processing to impart functions such as antibacterial agents, deodorants, insect repellents, phosphorescent agents, retroreflective agents, and negative ion generating agents.

[0028] The thus obtained woven fabric contains the composite yarn, and therefore has excellent elasticity and anti-pilling properties as well as flame retardancy. In this case, the composite yarn is preferably used as the weft yarn. In particular, the entire amount of the composite yarn is preferably used as the weft yarn. Also, the spun yarn as described above is preferably used as the warp yarn.

[0029] Here, the stretchability of the woven fabric is preferably such that the elongation rate of the warp and weft of the woven fabric in the direction in which the composite yarn is arranged is within the range of 10 to 50%. The elongation recovery rate of the woven fabric is preferably such that the elongation recovery rate of the warp and weft of the woven fabric in the direction in which the composite yarn is arranged is 70% or more (more preferably 73 to 99%). The flame retardancy of the woven fabric is preferably such that the limiting oxygen index measured according to JIS K7201 is 28 or more (more preferably 29 to 40). The char length specified in accordance with JIS L1091-1999 A-4 Method Appendix 8 is preferably 10 cm or less, and the residual flame and residual dust are preferably 2 seconds or less. The basis weight of the woven fabric is preferably 280 g / m2 in terms of light weight. 2 Less than or equal to 150 to 250 g / m 2 In addition, it is preferable that the anti-pilling property measured by JIS L1076-2012 Method A ICI type 10 hours is grade 4 or higher.

[0030] 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 anti-pilling properties. 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

[0031] 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.

[0032] (1) Flame retardancy The limiting oxygen index (LOI) was measured according to JIS K7201:1999 (combustion test method for polymeric materials using the oxygen index method) and used as an index of flame retardancy. The LOI was measured after washing five times and drying according to the JIS L1930:C4M method.

[0033] (2)Stretchability The elongation rate and elongation recovery rate were measured according to JIS L1096-2010 (Method B, constant load method).

[0034] (3) Flammability The flame time (seconds), afterglow time (seconds), and char length (cm) were measured as indicators of flammability according to JIS L1091-1999 A-4 Method Appendix 8. The LOI was measured after washing five times and drying according to JIS L1930: C4M method.

[0035] (4) Anti-pilling test The anti-pilling property (grade) was measured according to JIS L1076-2012 Method A (ICI 10 hr).

[0036] (5) Fineness Measured according to JIS L1013-2010 correct fineness.

[0037] (6) Elemental analysis of content concentration The phosphorus atom concentration in the composite fiber was quantitatively analyzed by washing the fabric five times according to the JIS L1930:C4M method, extracting the composite fiber from the dried fabric, setting the cross section in a scanning electron microscope (SEM, Hitachi Instruments Services S570 model) and connecting it to an energy dispersive X-ray microanalyzer (XMA, Horiba EMAX-7000).

[0038] (Spun yarn) A spun yarn was produced using meta-type wholly aromatic polyamide fiber (manufactured by Teijin Limited, trade name "Technora", single fiber fineness 1.7 dtex, fiber length 51 mm) to which a known phosphorus-based flame retardant had been added by a known method, and para-type wholly aromatic polyamide fiber (manufactured by Teijin Limited, trade name "Technora", single fiber fineness 1.7 dtex, fiber length 51 mm), with a twist number of 24 turns / 2.54 cm (twist direction Z), British cotton count of 40 / 1 (total fineness 147.6 dtex), and twist factor of 292, so that the content was 95% by weight of meta-type wholly aromatic polyamide fiber and 5% by weight of para-type wholly aromatic polyamide fiber.

[0039] (Composite fiber yarn) A polyester-based elastic yarn (Teijin Frontier's Solotex EcoHybrid (product name), a yarn made of 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.

[0040] [Example 1] The spun yarn was twisted in the S direction with a double twister with the number of final twists shown in Table 1, and then twist-stopped and set in a vacuum steam setting machine at a setting temperature of 120° C. for a setting time of 20 minutes to obtain warp yarn. On the other hand, the spun yarn and the composite fiber were combined and twisted in the S direction using a double twister with the number of twists shown in Table 1. The yarn was then twist-set using a vacuum steam setting machine at a setting temperature of 70°C for a setting time of 20 minutes, as shown in Table 1, to obtain a weft yarn.

[0041] The warp and weft yarns were used to weave the fabric with the weft and weft density shown in Table 1, and the fabric was singed, scoured, and set (temperature 150°C x time 30 seconds). The polyester fiber was heat-treated in a dye bath containing 1% owf disperse dye [CI Disperse Blue 56], 0.5g / L of disperse leveling agent [Nicca Chemical Co., Ltd., Nikka Sunsalt RM-340E], 0.3mL / L of 80% acetic acid, and 3% owf of Nicca Phineon HF-0350 (phosphorus-based flame retardant) at a bath ratio of 1:15 and a temperature of 130°C for 30 minutes using a liquid flow dyeing machine. After dyeing, the fabric was dried and set at the same width (temperature 180°C x time 30 seconds). The evaluation results are shown in Table 1.

[0042] [Examples 2 to 4] The same procedure was followed as in Example 1, except that the structure and hue of the fabric were changed. The evaluation results are shown in Table 1. Wefts were collected from the woven fabrics of Examples 1 to 4, and the fiber cross sections were analyzed with a scanning electron microscope (SEM, Hitachi Instruments Services Model S570). As a result, it was confirmed that phosphorus atoms derived from the flame retardant were present.

[0043] [Comparative Example 1] The same procedure was followed as in Example 1, except that a dye bath not containing NIKKKA PHAINON HF-0350 was used. The evaluation results are shown in Table 1. A weft yarn was taken from the woven fabric of Comparative Example 1, and the cross section of the composite fiber was analyzed with a scanning electron microscope (SEM, Hitachi Measuring Instruments Service Model S570). As a result, no phosphorus atoms derived from the flame retardant were confirmed.

[0044] [Table 1] [Industrial Applicability]

[0045] INDUSTRIAL APPLICABILITY According to the present invention, there are provided a woven fabric having not only flame retardancy but also excellent stretchability, anti-pilling properties and appearance quality, and a textile product using said woven fabric, and the industrial value thereof is extremely great.

Claims

1. A woven fabric comprising a composite yarn including a spun yarn containing a meta-type wholly aromatic polyamide fiber containing a flame retardant as a flame retardant fiber, and a yarn made of a composite fiber containing the flame retardant and in which two components are bonded together in a side-by-side or eccentric core-sheath type.

2. The woven fabric according to claim 1, wherein the flame retardant fiber is in the range of 65 to 85% by weight of the woven fabric, and the weight ratio of the composite fiber is in the range of 15 to 35% by weight of the woven fabric.

3. 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.

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

5. The woven fabric according to claim 1, wherein the elongation rate of the warp and weft of the woven fabric in the direction in which the composite yarn is arranged is within a range of 10 to 50%.

6. 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 and weft yarns of the woven fabric is 70% or more.

7. The fabric weight is 280 g / m ２ 2. The woven fabric of claim 1 , wherein:

8. The woven fabric according to claim 1, having an anti-pilling property of grade 4 or higher as measured by JIS L1076-2012 Method A ICI type 10 hours.

9. 2. The woven fabric according to claim 1, which has a limiting oxygen index of 28 or more as measured in accordance with JIS K7201.

10. A textile product made using the woven fabric according to any one of claims 1 to 9, 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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