Hot melt type resin composition for flameproofing, and flameproof fabric using the resin composition

Abstract

To provide a non-halogen-based hot melt type resin composition for flameproofing which can effectively impart flame proofness and fraying prevention performance.SOLUTION: A hot melt type resin composition for flameproofing is used for flameproofing a fibrous material, wherein (1) the resin composition contains a polyester-based hot melt resin having a melting point of 100°C or higher and an organic phosphorus-based flameproofing component having a melting point of 150°C or lower, (2) the total amount of the polyester-based hot melt resin and the organic phosphorus-based flameproofing component in the resin composition is 80 to 100 wt.%, (3) the content of the polyester-based hot melt resin in the resin composition is 50 to 95 wt.%, and (4) the content of the organic phosphorus-based flameproofing component in the resin composition is 3 to 50 wt.%.SELECTED DRAWING: None

Description

[Technical field]

[0001] The present invention relates to a novel hot-melt type flame-retardant resin composition and a flame-retardant fabric using the resin composition. [Background technology]

[0002] For example, in fabrics used in vehicle seats for automobiles, trains, etc., a backcoat agent, which is an aqueous dispersion containing an acrylic resin, a urethane resin, etc., and a flame retardant, is applied to the back of the fabric for the purpose of imparting flame retardancy and preventing fraying (for example, Patent Documents 1 to 3). Here, "fraying" refers to a state in which the stitching of the fibers constituting the fabric, etc., becomes disordered or the fibers protrude from the surface during processing (the manufacturing stage for vehicle seats, etc.) or during use of the product in the fabric, etc. that has been flame retardant-treated, etc.

[0003] In particular, with regard to polyester fabrics used in car seats, due to the high demand for flame retardancy in the seat fabric, it has become common to use a backcoat agent that has a flame retardant pre-mixed therein (hereinafter also referred to as a "flame-retardant BC agent") to seal the fabric (to prevent fraying) and perform flame retardancy processing at the same time.

[0004] In recent years, the above method has also been adopted in many cases for synthetic leather sheets made of urethane, etc. However, since there is almost no risk of fraying in synthetic leather sheets, backcoating is carried out simply to impart flame retardancy.

[0005] The flame-retardant BC agent used in such backcoat treatments usually contains about 40 to 80% by weight of moisture, so a drying process is required after coating. In order to carry out the drying process, it is necessary to install a drying oven in the production facility, and energy costs are also incurred to obtain the temperature required for drying.

[0006] In response to this, non-aqueous flame-retardant BC agents have also been proposed. For example, there is a method of using a flame-retardant BC agent containing a hot-melt resin for the purpose of imparting flame retardancy (Patent Document 4). In addition, a method of combining a polyester-based hot-melt resin with a halogen-based flame retardant is also known (Patent Document 5). These methods have the advantage that the flame-retardant BC agent is not used in the form of an aqueous dispersion, and therefore the drying process can be omitted. [Prior art documents] [Patent documents]

[0007] [Patent Document 1] International Publication WO2015 / 93606 [Patent Document 2] Patent Publication No. 2020-164715 [Patent Document 3] Patent Publication No. 2021-54924 [Patent Document 4] Patent Publication 2011-25130 [Patent Document 5] Patent Publication No. 63-94836 Summary of the Invention [Problem to be solved by the invention]

[0008] Hot melt resin is a type of adhesive, a thermoplastic resin that becomes liquid when heated and then solidifies again when cooled. Taking advantage of this property, it is possible to bond adherends together, and it is an adhesive with a very long history. In addition, since it does not contain organic solvents, water, or other solvents, there is no need for a drying process, and there is very little concern about the generation of VOCs (volatile organic compounds) from the materials used, making it an adhesive with extremely high environmental adaptability.

[0009] In addition, hot melt resins can be liquefied again by heating after application (use), so they can be used as an adhesive when attaching backing materials (urethane foam, etc.) in the next process. In addition, when recycling, the backing material can be easily peeled off by reheating, so there are many benefits, such as improved sorting and recyclability.

[0010] However, even in conventional flame-retardant BC agents using hot-melt resins, there is still room for further improvement.

[0011] In Patent Document 4, the focus is not on the selection of the type of hot melt resin, and as a result, a large amount of flame retardant is required to obtain the required flame retardancy, which is costly. In addition, the incorporation of a large amount of flame retardant results in a decrease in fraying prevention performance, so that the product can be used only in applications that do not require fraying prevention performance.

[0012] In Patent Document 5, due to the characteristics of its composition, the viscosity is relatively high, which causes problems with coating, and the coating amount tends to be very large, which is disadvantageous in terms of cost. In addition, since a halogen-based flame retardant is essential, there are also environmental problems. Moreover, halogen-based flame retardants are not thermally stable and generate a small amount of acid. Moreover, due to the nature of hot melt resin processing, it is necessary to maintain a molten state for a long time during the process, and in that case, problems such as deterioration of physical properties and coloring are likely to occur.

[0013] Here, according to the research of the present inventor, it has been confirmed that, with the BC agent of a conventional hot melt resin, when the hot melt resin is backed onto the back surface of a polyester fabric, for example, a certain degree of fraying prevention effect is observed, but it is difficult to obtain all the performance properties such as heat resistance and processing characteristics. For example, if a hot melt resin has a low softening point, there is no problem with the texture or processing characteristics, but when it is used for an automobile interior material such as a car seat, a certain degree of heat resistance is required, and there are problems such as the resin softening during a heat resistance test and the fraying prevention effect being lost, and so far only a very limited number of them have been put to practical use.

[0014] Furthermore, when imparting flame retardancy to a hot melt resin, a commonly considered method is to knead a flame retardant into the resin. However, the addition of a flame retardant changes the fluidity of the resin, significantly worsening its coatability, and as a result, it is not possible to stably obtain the original objectives of preventing fraying and flame retardancy.

[0015] SUMMARY OF THE PRESENT DISCLOSURE OF THE PRESENT DISCLOSURE Accordingly, a primary object of the present invention is to provide a non-halogen flame-retardant hot-melt resin composition which can more effectively impart flame retardancy and fray prevention properties. [Means for solving the problem]

[0016] Means of the Invention The present inventors have conducted extensive research in light of the problems in the prior art and have found that a resin composition having a specific composition can achieve the above object, thereby completing the present invention.

[0017] That is, the present invention relates to the following flame-retardant hot-melt resin composition and a flame-retardant fabric using the resin composition. 1. A resin composition used to make fibrous materials flame retardant, (1) A polyester hot melt resin having a melting point of 100°C or higher and an organic phosphorus flame retardant having a melting point of 150°C or lower, (2) In the resin composition, the total amount of the polyester hot-melt resin and the organic phosphorus flame-retardant component is 80 to 100% by weight, (3) the content of the polyester-based hot melt resin in the resin composition is 50 to 95% by weight, (4) The content of the organic phosphorus-based flame retardant component in the resin composition is 3 to 50% by weight. A flame-retardant hot melt type resin composition comprising: 2. The flame-retardant hot-melt resin composition according to item 1, further comprising a phosphorus- and / or nitrogen-based flame-retardant component having a melting point of 200° C. or higher. 3. The flame-retardant hot-melt resin composition according to claim 1, wherein a kneading torque in a kneader at a temperature of 180°C is 1.1 N·m or less. 4. A flame-retardant fiber product comprising a fibrous material and the flame-retardant hot-melt resin composition according to any one of items 1 to 3. 5. The flame-retardant fiber product according to claim 4, which is used as an interior material for a vehicle. 6. A method for producing a flame-retardant fiber product by coating a fibrous material with the flame-retardant hot-melt resin composition according to any one of items 1 to 3, comprising a step of coating a molten flame-retardant hot-melt resin composition onto the fibrous material at a coating temperature of 150 to 220°C. Effect of the Invention

[0018] According to the present invention, it is possible to provide a non-halogen flame-retardant hot-melt resin composition which can more effectively impart flame retardancy and fray prevention properties.

[0019] In particular, the flame-retardant hot-melt resin composition of the present invention is made by combining a polyester hot-melt resin having a specific melting point with an organic phosphorus-based flame-retardant component having a relatively low melting point, and the phosphorus-based flame-retardant component not only functions to impart flame retardancy during use, but also functions as a plasticizer in the composition, so that when melted, it exhibits a viscosity (fluidity) suitable for coating, and thus excellent coatability can be obtained. In other words, it becomes possible to coat the surface of a fibrous material more uniformly.

[0020] In addition, the flame-retardant hot-melt resin composition of the present invention is a type that is melted and used, so unlike conventional water-based backing agents, the drying process and drying equipment after coating can be omitted. For example, the drying process that is essential for flame-retarding and fraying prevention processing of car seats using water-based BC agents is not required. As a result, the energy cost required for drying is reduced, and the space required for production can be significantly reduced as the installation of a large drying oven becomes unnecessary. In this regard, one of the Sustainable Development Goals (SDGs) is Goal 7 "Affordable and Clean Energy," which emphasizes the use of clean energy as well as the importance of energy conservation. Therefore, the flame-retardant hot-melt resin composition of the present invention, which can contribute to energy reduction, can also meet the above-mentioned requirements of the SDGs.

[0021] Furthermore, since the flame-retardant hot-melt resin composition of the present invention is composed of a non-halogen-based composition, it is possible to avoid pollution of the working environment, etc., and also to avoid problems such as discoloration due to halogens.

[0022] The flame-retardant hot-melt resin composition of the present invention is mainly composed of a recyclable polyester resin, so that the environmental load can be reduced. In particular, when a polyester-based fibrous material is used as the fibrous material, the flame-retardant hot-melt resin composition can be recycled together with the fibrous material. In this respect, it can be said that the material is in line with the Sustainable Development Goals (SDGs). DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0023] 1. Flame-retardant hot melt resin composition The flame-retardant hot melt resin composition of the present invention (the composition of the present invention) is a resin composition used for making a fibrous material flame-retardant, (1) A polyester hot melt resin having a melting point of 100°C or higher and an organic phosphorus flame retardant having a melting point of 150°C or lower, (2) In the resin composition, the total amount of the polyester hot-melt resin and the organic phosphorus flame-retardant component is 80 to 100% by weight, (3) the content of the polyester-based hot melt resin in the resin composition is 50 to 95% by weight, (4) The content of the organic phosphorus-based flame retardant component in the resin composition is 3 to 50% by weight. It is characterized by:

[0024] (1) Polyester-based hot melt resin The polyester hot-melt resin used in the present invention is a polyester hot-melt resin having a melting point of at least 100° C. Here, the melting point in the present invention refers to the melting point (Tm) measured by a differential scanning calorimeter (DSC).

[0025] Conventionally, hot melt resins include various types such as polyester, ethylene vinyl acetate copolymer (EVA), polyolefin, styrene butadiene rubber (SBR), acrylic, and polyamide, but the present invention uses a polyester hot melt resin.

[0026] In addition to having a relatively high melting point (softening point), polyester hot melt resins have very good adhesion to polyester fibers and can be easily made flame retardant. Moreover, polyester hot melt resins have the advantage that they can be chemically recycled into monomers under the same conditions as polyester fibers when the fibers are recycled.

[0027] The type of polyester resin constituting the polyester-based hot melt resin is not particularly limited, and examples thereof include various polyester-based resins obtained by condensation polymerization of polycarboxylic acids such as terephthalic acid, isophthalic acid, phthalic acid, α-naphthalenedicarboxylic acid, β-naphthalenedicarboxylic acid, succinic acid, glutaric acid, adipic acid, sebacic acid, and dodecanedioic acid with polyhydric alcohols such as ethylene glycol, propylene glycol, butanediol, pentanediol, diethylene glycol, triethylene glycol, dipropylene glycol, and neopentyl glycol, and one or more of these may be used.

[0028] The polyester resin is not limited to, and examples thereof include polyethylene terephthalate, polybutylene terephthalate, polyethylene naphthalate, polytrimethylene terephthalate, and modified resins thereof. These may be used alone or in combination of two or more.

[0029] Such polyester-based hot melt resins may be publicly known or commercially available. Commercially available products include, for example, hot melt adhesives. Specific examples include products with the names "Aronmelt PES-120L", "Aronmelt PES-140H", and "Aronmelt PES-111EE" (all manufactured by Toagosei Co., Ltd.), "Nichigo Polyester SP-154", "Nichigo Polyester SP-176", and "Nichigo Polyester SP-160" (all manufactured by Mitsubishi Chemical Corporation).

[0030] The content of the polyester hot melt resin in the composition of the present invention is usually about 50 to 95% by weight, and preferably 60 to 90% by weight, which can more reliably obtain flame retardant performance and fray prevention effect.

[0031] (2) Organophosphorus flame retardant components The composition of the present invention contains an organic phosphorus-based flame-retardant component (first flame-retardant component) having a melting point of 150° C. or lower as a flame-retardant component.

[0032] As mentioned above, polyester-based hot melt resins have a high softening point, so they can perform well even in the high-temperature range used as vehicle interior materials. However, these resins generally have a high viscosity when melted, which causes problems with coating. That is, problems such as a) the resin cannot be applied uniformly to the fabric, resulting in uneven coating, b) the resin becomes surface-attached, which reduces the ability to prevent fraying, and c) the resin requires force to separate the coating roll from the fabric, which causes parts of the fabric to break. In general, there are cases where the above-mentioned problems can be solved by increasing the coating temperature and decreasing the coating viscosity, but when the target adherend is, for example, polyester fabric, coating at 200°C or less is suitable due to its heat resistance, and the improvement in coating temperature is very limited. In addition, when a powdered flame retardant is added to the hot melt resin to impart flame retardancy, the melt viscosity becomes even higher, making it virtually impossible to apply the resin to polyester fabric. In contrast, in the present invention, an organic phosphorus-based flame retardant with a melting point of 150°C or less is pre-kneaded into the resin, which not only imparts flame retardancy but also adjusts the viscosity to a level suitable for coating, thereby more reliably eliminating the above-mentioned problems.

[0033] In addition, the first flame retardant component is preferably a halogen-free compound. Therefore, among the organic phosphorus-based flame retardant components, compounds that do not contain halogen atoms can be suitably used. Even with halogen-based flame retardants, agents with low melting points (150°C or less) are commercially available, and the effect of reducing the melt viscosity of hot melt resins can be expected in the same way as with organic phosphorus-based flame retardants. However, from the viewpoint of environmental consideration, the use of halogen-based flame retardants is avoided and is not preferred. In addition, low-melting-point halogen-based flame retardants generate a small amount of hydrogen halide by thermal decomposition when heated. In the coating process envisioned in the present invention, the flame retardant may be melted for a relatively long time, and there is a concern that the flame retardant may discolor and deteriorate during that time, so this is not recommended.

[0034] The organic phosphorus-based flame retardant component is not particularly limited, and may be, for example, at least one of orthophosphate, condensed phosphate, phosphonate, etc. Among these, condensed phosphate is preferable from the viewpoint of heat resistance.

[0035] As the organic phosphorus-based flame retardant component, commercially available products can be used, such as those under the product names "CR-741" and "PX-200" (both manufactured by Daihachi Chemical Industry Co., Ltd.), "ADK STAB FP-600" and "ADK STAB FP-900L" (both manufactured by ADEKA Corporation).

[0036] The content of the organic phosphorus-based flame retardant component in the composition of the present invention is not particularly limited as long as the above ratio is satisfied, but is usually about 3 to 50% by weight, and preferably 10 to 30% by weight, which allows the organic phosphorus-based flame retardant component to effectively provide flame retardancy and a plasticizer-like effect.

[0037] In the composition of the present invention, the total content of the organic phosphorus flame retardant component and the polyester hot melt resin is usually 80 to 100% by weight, and preferably 85 to 95% by weight, which allows the properties of both components to be effectively utilized in the composition of the present invention.

[0038] Furthermore, the ratio of the polyester hot melt resin to the organic phosphorus flame retardant component is not particularly limited, but is preferably 5 to 70 parts by weight (preferably 10 to 50 parts by weight) of the organic phosphorus flame retardant component to 100 parts by weight of the polyester hot melt resin. This not only provides the effect of flame retardancy and preventing fraying, but also effectively suppresses bleeding out of the flame retardant component onto the coated surface after cooling, generation of tackiness, etc.

[0039] (3) Other flame retardant components In the present invention, if necessary, a flame retardant component other than the first flame retardant component can be blended. Such flame retardant components are not limited, but in the present invention, a phosphorus and / or nitrogen-based flame retardant component (second flame retardant component) having a melting point of 200° C. or more can be preferably used in combination. This makes it possible to further increase the flame retardancy and more effectively suppress the tackiness of the coating surface.

[0040] The second flame retardant component may be a compound containing at least one of a phosphorus atom and a nitrogen atom, and may therefore be a compound containing both a phosphorus atom and a nitrogen atom in one compound.

[0041] In addition, the second flame retardant component is preferably a halogen-free compound for the same reason as the first flame retardant component. That is, although there are halogen-based flame retardants with high melting points, their use is not recommended from the viewpoint of environmental consideration. In addition, coloring or resin deterioration due to the generation of hydrogen halide by long-term heating is less than that of low melting point types, but it still occurs.

[0042] Specific examples of the second flame retardant component are not particularly limited and may be either organic compounds or inorganic compounds. For example, at least one of phosphoric acid amidate compounds, phosphonic acid ester compounds, metal phosphinate salts, melamine cyanurate (MCA), melamine polyphosphate (MPP), etc. may be mentioned. These may also be commercially available products. In the present invention, among these, at least one of phosphoric acid amidate compounds, phosphonic acid ester compounds, metal phosphinate salts, etc. is preferred as the second flame retardant component.

[0043] The amount of the second flame retardant component added is not particularly limited, but is usually about 3 to 15% by weight, and preferably 5 to 10% by weight, in the composition of the present invention, allowing the second flame retardant component to effectively perform its function.

[0044] The ratio of the second flame retardant component to the first flame retardant component is not limited, but is preferably about 5 to 100 parts by weight, and more preferably 10 to 80 parts by weight, per 100 parts by weight of the first flame retardant component, which provides higher flame retardancy, excellent fraying prevention effect, good coatability, etc.

[0045] (4) Other additives The composition of the present invention may contain other additives within the range that does not impair the effects of the present invention. Examples of such additives include plasticizers, dispersants, preservatives, deodorants, water repellents, oil repellents, crosslinking agents (isocyanate-based, ethyleneimine-based, glycidyl-based), antioxidants, UV absorbers, light (weather) resistance agents, pigments and dyes, antistatic agents, antibacterial agents, antiviral agents, nucleating agents, etc. The amount (total amount) of these additives may be, for example, 5% by weight or less, but is not limited thereto.

[0046] Among these additives, it is particularly preferred that the composition of the present invention contains an antioxidant. The antioxidant is not particularly limited, but may be at least one of a phenolic compound, a phosphite compound, a thioether compound, or the like. Among these, at least one of a hindered phenolic antioxidant and a phosphite antioxidant can be suitably used in the present invention. In particular, it is more preferred to use both a hindered phenolic antioxidant and a phosphite antioxidant in combination, in that they can effectively maintain stability in a high-temperature environment (during coating) and long-term stability (product stability over time) in the normal temperature range.

[0047] The content (total amount) of the antioxidants in the composition of the present invention is not limited, but may usually be about 0.1 to 0.5% by weight. When both a hindered phenol-based antioxidant and a phosphite-based antioxidant are used in combination, the content may be about 0.05 to 0.2% by weight, but is not limited thereto.

[0048] Although the composition of the present invention generally does not contain water, it may contain a small amount of water as long as it does not impede the effects of the present invention. For example, a water content of 1% by weight or less (particularly 0.1% by weight or less) is an amount acceptable for the present invention.

[0049] As described above, the composition of the present invention as a whole is preferably non-halogenated (does not contain halogen elements), and therefore, it is desirable to use non-halogenated compounds for components (additives, etc.) other than the polyester-based hot melt resin and the organic phosphorus-based flame retardant component.

[0050] (5) Characteristics and Form of the Composition of the Present Invention The composition of the present invention desirably has a kneading torque of 1.1 N·m or less (particularly 1.0 N·m or less) when kneaded at a temperature of 180°C. This allows an appropriate viscosity (fluidity) to be obtained when applied to a fibrous material, resulting in good coatability. In other words, the composition of the present invention can be uniformly applied to the surface of the fibrous material. The lower limit of the kneading torque can be, for example, about 0.1 N·m, but is not limited thereto.

[0051] The kneading torque can be measured, for example, using a C-type Laboplastomill "4C150" manufactured by Toyo Seiki Seisakusho. The C-type Laboplastomill is a type of torque rheometer that can estimate the processability of various materials by dynamic measurement while feeding them into a small mixer and applying shear under heated conditions. Its greatest feature is that it can obtain measurement data close to on-site production processing with a small amount of sample.

[0052] 2. Method for producing flame-retardant hot-melt resin composition The composition of the present invention can be obtained by uniformly mixing these components. In particular, the composition of the present invention can be suitably produced by a method including a step of obtaining a melt-kneaded product by heating a raw material containing a polyester hot-melt resin and an organic phosphorus flame-retardant component to a temperature equal to or higher than the melting point (Tm) of the polyester hot-melt resin (preferably [Tm+5]°C or higher, more preferably [Tm+10]°C or higher, and most preferably [Tm+20]°C or higher). Therefore, for example, if the melting point of the polyester hot-melt resin is 120°C, the melt-kneaded product can be suitably obtained by heating at 140°C or higher. The upper limit of the heating temperature can be, for example, about 220°C, but is not limited thereto.

[0053] The production of the melt-kneaded product is not particularly limited as long as it is an apparatus capable of heating, and for example, known or commercially available kneading apparatus such as a mixer, a kneader, or a mixing roll can be used.

[0054] The molten mixture is solidified by cooling, but can also be processed and molded into pellets, granules, sheets, powder, etc., as needed. In this way, a solid composition (compound) in which the polyester hot melt resin, the organic phosphorus flame retardant component, etc. are uniformly mixed can be provided. This can also be processed into powder, granulated, etc., as needed.

[0055] 3.Flame-retardant textile products The present invention includes a flame-retardant fiber product comprising a fibrous material and the flame-retardant hot-melt resin composition of the present invention.

[0056] The form of the fibrous material is not limited, but is preferably in the form of fabric such as woven fabric, knitted fabric, nonwoven fabric, etc. (sheet-like material such as cloth or fabric).

[0057] The product form (use) of the fibrous material is also not limited, and may be, for example, any of fabrics for seats, interior materials, interiors, industrial materials, etc. for automobiles, trains, ships, aircraft, etc. In particular, the present invention is suitable for use as a fibrous material used as an interior material for vehicles, which requires high flame retardancy.

[0058] The fibers constituting the fibrous material may be any of synthetic fibers, semi-synthetic fibers, and natural fibers, but from the viewpoints of affinity with the flame-retardant hot melt resin composition, ease of recycling, and the like, fibrous materials containing synthetic fibers are preferred, and fibrous materials containing polyester-based fibers are more preferred. Examples of polyester-based fibers include, but are not limited to, polyethylene terephthalate, polybutylene terephthalate, polyethylene naphthalate, polytrimethylene terephthalate, and the like, as well as synthetic fibers produced from modified resins thereof. Therefore, as a fibrous material, the composition of the present invention can be suitably applied to fabrics (cloths, fabrics) containing polyester-based fibers. The fabric may have a basis weight of, for example, 30 to 500 g / m. 2 It can be, but is not limited to, the degree.

[0059] Furthermore, the fabric containing polyester-based fibers may be, for example, a fabric containing 100% by weight of polyester-based fibers, but may also contain a) fibers such as a mixed resin of polyester resin with other synthetic resins, etc., or a polymer alloy, or b) fibers blended with polyester-based fibers and other synthetic fibers or natural fibers (cotton, silk, hemp, etc.), as long as the effects of the present invention are not impaired.

[0060] The fiber form may be either short fiber or long fiber. The fiber diameter is not limited and may be, for example, about 5 to 50 μm, but is not limited thereto.

[0061] The amount of the flame-retardant hot-melt resin composition of the present invention applied to a fibrous material can be appropriately determined depending on the desired flame retardancy, the type of fibrous material, etc., but is usually 10 to 100 g / m 2 Approximately 20 to 80 g / m 2 It is preferable to set the thickness to 30 to 60 g / m2 By setting the content within this range, it is possible to effectively obtain both the flame retardant effect and the fraying prevention effect at the same time.

[0062] 4. Manufacturing method of flame-retardant textile products The flame-retardant fiber product of the present invention can be obtained by applying the composition of the present invention to a fibrous material. In particular, the flame-retardant fiber product can be preferably produced by a method for producing a flame-retardant fiber product by coating a fibrous material with the flame-retardant hot-melt resin composition of the present invention, which includes a step of coating a molten product of the flame-retardant hot-melt resin composition on the fibrous material at a coating temperature of 150 to 220°C.

[0063] The flame-retardant hot-melt resin composition can be heated at 150 to 220° C. to prepare a melt. As described above, the heating temperature can be appropriately set within the above range depending on the melting point of the polyester hot-melt resin in the flame-retardant hot-melt resin composition. In particular, in the present invention, it is preferable to heat the fibrous material at a low temperature range in order to maintain the quality of the fibrous material.

[0064] The coating method is not particularly limited, and may be, for example, a roll coater, a knife coater, a gravure coater, a kiss coater, various applicators, etc. Among these, in the present invention, from the viewpoint of uniform coating properties and versatility, a roll coater, a knife coater, etc. are particularly preferably used.

[0065] The coating is preferably carried out as a so-called back coat, that is, the composition of the present invention is preferably applied to the area that will be the back surface of the fibrous material when it is made into a product.

[0066] After the molten material is applied at the above temperature, it is cooled to obtain a flame-retardant fiber product in which the fibrous material is covered or impregnated with the solidified flame-retardant hot-melt resin composition. EXAMPLES

[0067] The features of the present invention will be described in more detail below with reference to examples and comparative examples. However, the scope of the present invention is not limited to the examples. In the examples, "%" means "% by weight".

[0068] 1.Ingredients used (1) Hot melt resin (raw material A) "Aronmelt PES-120L" (manufactured by Toa Gosei Co., Ltd., polyester-based hot melt resin, melting point approx. 120°C, Tg=-10°C, melt viscosity 30,000mPa·s (190°C)) "Aronmelt PES-140H" (manufactured by Toagosei Co., Ltd., polyester-based hot melt resin, melting point approx. 145°C, Tg=-4°C, melt viscosity 80,000mPa·s (190°C)) "Nichigo Polyester SP-154" (Mitsubishi Chemical Corporation, polyester hot melt resin, melting point approx. 120°C, Tg = -20°C, melt viscosity 150,000 mPa·s (190°C)) "Technomelt AS5375" (manufactured by Henkel Japan Ltd., polyolefin hot melt resin, melting point approx. 140°C, melt viscosity 4,500mPa·s (180°C)) (2) First flame-retardant component (raw material B) "CR-741" (manufactured by Daihachi Chemical Industry Co., Ltd., condensed phosphate ester, melting point 4-5°C) "PX-200" (manufactured by Daihachi Chemical Industry Co., Ltd., condensed phosphate ester, melting point approx. 92°C) "ADEKA STAB FP-900L" (ADEKA Corporation, condensed phosphate ester, room temperature viscous liquid) (3) Second flame retardant component (raw material C) "Daiguard-850" (manufactured by Daihachi Chemical Industry Co., Ltd., aliphatic phosphate amidate, melting point approximately 259°C) "Fireguard FCX-210" (Teijin Limited, phosphonic acid ester, melting point 254°C or higher) "Exolit OP-930" (Clariant Japan Co., Ltd., organic phosphinate, melting point not indicated) "MC-6000" (Nissan Chemical Co., Ltd., melamine cyanurate, melting point not indicated) (4) Antioxidants "ADEKA STAB AO60" (ADEKA Corporation, hindered phenol-based antioxidant) "ADEKA STAB 2112" (ADEKA Corporation, phosphite antioxidant)

[0069] 2. Equipment used (1) Mixing machine Labo Plastomill 4C150 (manufactured by Toyo Seiki Co., Ltd.) (2) Roll coater · Roll coater FR300 (Fast Corporation)

[0070] 3. Examples and Comparative Examples [Examples 1 to 9 and Comparative Examples 1 to 7] The ingredients A to C were weighed out to obtain the compositions shown in Tables 1 and 2 (the "%" in the tables indicates % by weight), and then, using a kneader, ingredient A was melt-kneaded at 130 to 150°C. To this molten resin component, antioxidants (0.1% each of AO60 and A2112) were added, and ingredient B was then added. Furthermore, ingredient C was slowly added as necessary, and after the addition was completed, the mixture was kneaded at the same temperature for 5 minutes to prepare a mixture. After kneading, the resulting mixture was scraped onto a release PET (polyethylene terephthalate) film and allowed to cool naturally, yielding a block of a flame-retardant hot melt resin composition to be used in the test examples described below.

[0071] [Test Example 1] The flame-retardant hot-melt resin compositions prepared in each of the Examples and Comparative Examples were subjected to the following treatments and evaluations, and the results are shown in Tables 1 and 2.

[0072] (1) Torque measurement The kneading torque at the coating temperature was measured using a Labo Plastomill "4C150 (manufactured by Toyo Seiki Co., Ltd.) The mixer temperature was raised to the specified temperature (180 °C), 100 g of the resulting molten material was charged into the mixer and kneaded at a rotation speed of 50 rpm. After the content temperature reached the specified temperature, kneading was continued for about 1 minute, and the torque value (N m) after stabilization was read.

[0073] (2) Coating (preparation of coated fabric for testing) Polyester fabric (weight 300g / m 2 A black polyester fabric for car seats was subjected to a load treatment by immersing it in a 0.2% aqueous solution of a silicone-based sewing improver "POLON MF29 (manufactured by Shin-Etsu Chemical Co., Ltd.)" at a squeezing rate of 80%, to prepare the test base fabric (size 25cm x 40cm) used in this test. The flame-retardant hot melt resin composition was put into a roll coater (touch roll and main roll both set at 180°C), melted, and coated onto the test fabric. The coating amount was adjusted by appropriately adjusting the clearance between the rolls. The coating amount was determined from the change in weight of the fabric. In this case, the flame retardancy, etc. were also evaluated for a sample of the test base fabric that had not been coated at all (Reference Example 1) and a sample in which a conventional water-based BC agent was coated on the test base fabric (Reference Example 2). The results are also shown in Table 2.

[0074] (3) Evaluation of uniform coating properties The test base fabric (coated fabric) coated in the above (2) was visually inspected to see whether the hot melt resin was evenly applied to the test base fabric. The results were evaluated as follows: 〇…Uniform coating △: The coating is almost uniform, but some unevenness (streaks) can be seen. ×: Unevenness (streaks) can be seen over the entire test fabric.

[0075] (4) Flame retardancy evaluation The above sample (coated fabric) was cut into a size of 20cm x 35cm and acclimatized at 20℃ x 50% RH for more than 24 hours to prepare a sample for flame retardancy testing. The flame retardancy testing was conducted based on the FMVSS-302 method, which is a safety standard for automotive interior products. The number of tests was 20. The evaluation criteria were as follows: Test piece does not ignite or goes out before the A mark: "Non-flammable" - Burning distance is 51mm or less (and self-extinguishing within 60 seconds): "Flame retardant" Burning speed of 102mm / min or less: "Retarded" - Burning speed exceeds 102mm / min: "flammable" In Tables 1 and 2, the number of times each evaluation was performed is listed in the order of non-flammability / flame retardancy / flame retardancy / flammability. Fabric samples that were judged to be non-flammable through flame retardant and flammability only once out of 20 times were classified as "failed."

[0076] (5) Anti-fraying The above sample (coated fabric) was cut to a size of 20 cm x 5 cm and conditioned at 20°C x 50% RH for at least 24 hours to prepare a sample for the fraying prevention test. One warp thread (long side) was pulled out about 5 cm from a corner of the sample, and the maximum strength (N) measured while pulling out the remaining 15 cm using a tensile tester was used to evaluate the fraying prevention. In practice, it is desirable for the maximum strength to be 0.5 N or more (especially 0.6 N or more).

[0077] [Table 1]

[0078] [Table 2]

[0079] As is clear from the results in Table 1, in the examples containing a predetermined amount of a polyester-based hot melt resin and a first flame-retardant component (and a second flame-retardant component), excellent flame retardancy as well as good fraying prevention effects can be obtained. Moreover, the flame-retardant hot melt resin compositions of the examples show good coatability for polyester fiber fabrics. The coating viscosity correlates with the mixing torque in a Labo Plastomill, and coatability can be predicted from the mixing torque. In particular, in the examples, a relatively small coating amount (for example, 19 to 40 g / m 2 It can also be seen that even if the temperature is reduced to a certain level, high flame retardancy and fraying resistance can be maintained.

[0080] In contrast, when a polyester-based hot melt resin is used, as in the comparative examples, if the specified composition of the present invention is not satisfied, it is found that excellent flame retardancy and fray prevention properties cannot be obtained simultaneously.

[0081] In addition, when a polyolefin-based hot melt resin was used as in Comparative Examples 6 and 7, the flame retardancy was significantly reduced even though the flame retardant component was included. This fact also shows that, as in the present invention, the combination of a polyester-based hot melt resin and a predetermined flame retardant component can achieve excellent flame retardancy together with the fraying prevention effect.

Claims

1. A resin composition used for making a fibrous material flame retardant, (1) A polyester hot melt resin having a melting point of 100°C or higher and an organic phosphorus flame retardant component having a melting point of 150°C or lower, (2) In the resin composition, the total amount of the polyester hot melt resin and the organic phosphorus flame retardant component is 80 to 100% by weight, (3) The content of the polyester-based hot melt resin in the resin composition is 50 to 95% by weight, (4) The content of the organic phosphorus-based flame retardant component in the resin composition is 3 to 50% by weight. A flame-retardant hot melt type resin composition comprising:

2. 2. The flame-retardant hot-melt resin composition according to claim 1, further comprising a phosphorus- and / or nitrogen-based flame-retardant component having a melting point of 200° C. or higher.

3. 2. The flame-retardant hot-melt resin composition according to claim 1, wherein a kneading torque in a kneader at a temperature of 180° C. is 1.1 N·m or less.

4. A flame-retardant fiber product comprising a fibrous material and the flame-retardant hot-melt resin composition according to any one of claims 1 to 3.

5. The flame-retardant fiber product according to claim 4, which is used as an interior material for a vehicle.

6. A method for producing a flame-retardant fiber product by coating a fibrous material with the flame-retardant hot-melt resin composition according to any one of claims 1 to 3, comprising a step of coating a molten product of the flame-retardant hot-melt resin composition on the fibrous material at a coating temperature of 150 to 220°C.

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