Interior fabric and manufacturing method for interior fabric

Abstract

To provide an interior fabric having sufficient water-repellent performance by using a water-repellent agent and sufficient flame-retardant performance by using a flame-retardant agent.SOLUTION: An interior fabric which is one embodiment to which the present invention is applied, comprises: a fabric obtained by interweaving flame -retardant polyester fibers and non-flame-retardant polyester fibers; a flame-retardant adhered part in the fabric where a flame-retardant agent is adhered; an antibacterial agent applied surface on which an antibacterial agent is applied in one side of the fabric on which the flame retardant-adhered part is formed; and a water-repellent-applied surface on which a water-repellent agent is applied in the other side of the fabric on which the flame-retardant adhered part is formed.SELECTED DRAWING: Figure 3

Description

Technical Field

[0001] The present invention is used for interior decoration, and relates to an interior fabric having sufficient water repellency, flame retardancy, and antibacterial properties.

Background Art

[0002] Conventionally, as an interior fabric used for interior decoration of public facilities such as hotels and hospitals, there is a fabric made of polyester fiber, and it is obligatory to have the flame retardancy / flame retardant properties specified by the Fire Service Act. As the fiber constituting such an interior fabric, specifically, there is a polyester flame retardant fiber having high flame retardant properties by impregnating a polyester fiber with a flame retardant (see, for example, Patent Document 1). Further, as such an interior fabric, there is also one used as a shower curtain for bathrooms in hotels and the like, and it is required to have high water repellency and high antibacterial properties. As such an interior fabric, specifically, there is a fabric made of a mixed and interlaced yarn composed of two types of polyester fibers having different finenesses, and having high water repellency by attaching a water repellent to the unevenness on the surface (see, for example, Patent Document 2).

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Patent Document 2

Summary of the Invention

Problems to be Solved by the Invention

[0004] However, in such conventional interior fabrics, although it is necessary to have a fabric that combines sufficient performance in both water repellency and flame retardancy, generally, water repellents have the property of significantly reducing flame retardancy. Therefore, in particular, it has been difficult to achieve both performances by using a water repellent and a flame retardant. Also, in interior fabrics used for the interiors of public facilities such as hotels and hospitals, not only is it necessary to have sufficient water repellency performance and sufficient flame retardancy performance, but it is also desired to have sufficient antibacterial performance and sufficient odor prevention performance. However, there has also been a problem that it is difficult to achieve all four of these performances.

[0005] The present invention has been made in view of such problems, and an object thereof is to provide an interior fabric having sufficient water repellency performance using a water repellent and sufficient flame retardancy performance using a flame retardant. Another object is to provide an interior fabric having not only sufficient water repellency and sufficient flame retardancy performance, but also sufficient antibacterial performance and sufficient odor prevention performance.

Means for Solving the Problems

[0006] The present invention has been made to solve at least a part of the above-described problems and can be realized as the following application examples. The reference numerals and supplementary explanations in parentheses in this column are shown for the purpose of assisting the understanding of the present invention and showing the correspondence with the embodiments described later, and do not limit the present invention in any way.

[0007] An interior fabric, which is one of the application examples of the present invention, includes a fabric in which a flame-retardant polyester fiber and a non-flame-retardant polyester fiber are interwoven, a flame retardant adhering portion which is a portion of the fabric where a flame retardant is adhered, an antibacterial agent coating surface which is one surface of the fabric on which the flame retardant adhering portion is formed and on which an antibacterial agent is coated, and a water repellent coating surface which is the other surface of the fabric on which the flame retardant adhering portion is formed and on which a water repellent is coated.

[0008] In the interior fabric of the above application example, the fabric may be woven with 50.0% to 76.0% by weight of flame-retardant polyester fibers and 24.0% to 50.0% by weight of non-flame-retardant polyester fibers.

[0009] A method for manufacturing an interior fabric, which is one of the application examples of the present invention, is a method for manufacturing an interior fabric made of a fabric woven with flame-retardant polyester fibers and non-flame-retardant polyester fibers, and on one side and the other side of the fabric, a flame-retardant treatment for applying a flame retardant, an antibacterial treatment for applying an antibacterial agent on one side of the fabric subjected to the flame-retardant treatment, and a water-repellent treatment for applying a water-repellent agent on the other side of the fabric subjected to the flame-retardant treatment are carried out.

[0010] In the method for manufacturing the interior fabric of the above application example, the antibacterial treatment may be carried out by spraying an antibacterial agent on one side of the fabric subjected to the flame-retardant treatment so as to apply the antibacterial agent. Also, in the method for manufacturing the interior fabric of the above application example, the water-repellent treatment may be carried out by spraying a water-repellent agent on the other side of the fabric subjected to the flame-retardant treatment so as to apply the water-repellent agent. Furthermore, in the method for manufacturing the interior fabric of the above application example, the fabric may be woven with 50.0% to 76.0% by weight of flame-retardant polyester fibers and 24.0% to 50.0% by weight of non-flame-retardant polyester fibers.

Brief Description of the Drawings

[0011]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Figure 7

Embodiments for Carrying Out the Invention

[0012] Hereinafter, embodiments to which the present invention is applied will be described with reference to the drawings. Note that the embodiments of the present invention are not limited to the following embodiments at all, and various forms can be adopted as long as they belong to the technical scope of the present invention. as long as they belong to the technical scope of the present invention.

[0013] [Embodiment] <Method for Manufacturing Interior Fabric of the Present Embodiment> Referring to FIG. 1, first, the method for manufacturing the interior fabric of the present embodiment will be described. FIG. 1 is a flowchart for explaining the method for manufacturing the interior fabric 1 of the present embodiment. As shown in FIG. 1, in the method for manufacturing the interior fabric 1, a weaving process for producing a fabric, a pre-scouring process for removing impurities from the fabric produced in the weaving process, a flame-retardant treatment process for performing flame-retardant processing on the fabric, an antibacterial treatment process for performing antibacterial processing on the fabric, and a water-repellent treatment process for performing water-repellent processing on the fabric are executed. By executing these processes, the interior fabric 1 will be manufactured. Details of each process will be described below.

[0014] (1) Weaving process The weaving process is a process of producing a fabric by weaving warp yarns of flame-retardant polyester fibers and weft yarns of non-flame-retardant polyester fibers. In this embodiment, 50.0% to 76.0% by weight of flame-retardant polyester fibers are used, and 24.0% to 50.0% by weight of non-flame-retardant polyester fibers are used. More preferably, 59.8% to 75.9% by weight of flame-retardant polyester fibers are used, and 24.1% to 40.2% by weight of non-flame-retardant polyester fibers are used. Also, in this embodiment, as the flame-retardant polyester fibers, Super Ester (registered trademark) manufactured by Teijin Limited is used, and as the non-flame-retardant polyester fibers, Semidal SR manufactured by Teijin Limited is used. Further, as the weaving method performed in the weaving process, various conventionally used methods may be used, and thus the description of the method is omitted. In addition, as the flame-retardant polyester fibers, in addition to the above-mentioned Super Ester, Unfla (registered trademark) manufactured by Toray Industries, Inc., Crystal Flame Retardant Yarn manufactured by Kawabou Textile Co., Ltd., Flame Retardant BR manufactured by Yamakoshi Co., Ltd., etc. may be used. Also, as the non-flame-retardant polyester fibers, in addition to the above-mentioned Semidal SR, Inter SD of Yamakoshi Co., Ltd., etc. may be used.

[0015] (2) Pre-scouring process The pre-scouring process is a process of removing impurities from the fabric produced in the above-mentioned weaving process to enable the subsequent antibacterial treatment process, water repellent treatment process, and flame retardant treatment process. Specifically, in the pre-scouring process, after immersing the fabric in a scouring liquid at room temperature, the scouring liquid is heated to 80 to 90 °C between 5 and 10 minutes after the start of scouring. Then, it is washed with hot water at 60 °C for 1 to 2 minutes. As the scouring liquid, a mixture of 20 times the amount of water of the fabric, 3% of caustic soda of the fabric amount, and 1% of a neutral detergent of the fabric amount is used. In addition, in the pre-scouring process of this embodiment, the so-called general open soaper is used to scour the fabric.

[0016] (3) Flame retardant treatment process The flame-retardant treatment process is a process of applying a flame retardant to the fabric from which impurities have been removed in the above-described pre-refining process to add flame-retardant performance. Specifically, in the flame-retardant treatment process, the fabric in a rope shape is conveyed at 130 °C under high pressure together with a strong jet of the flame retardant generated in the tank, and the flame-retardant adhering part, where the flame retardant is adhered to the fibers of the fabric, is formed over the entire fabric by a so-called liquid flow dyeing method. That is, by applying the flame retardant to one side and the other side of the fabric, the flame-retardant adhering part is formed over the entire fabric (both sides). In this embodiment, as the flame retardant, Nonnen (registered trademark) CLB-10 manufactured by Marubishi Yuka Kogyo Co., Ltd. or Nikka Finon (registered trademark) HF-0350 manufactured by Nihon Kayaku Co., Ltd. is used as a halogen-based flame retardant. In the flame-retardant treatment process of this embodiment, a so-called general liquid flow dyeing machine is used to perform the flame-retardant treatment on the fabric. Further, in the flame-retardant treatment process of this embodiment, after the flame retardant is adhered to the fabric using the liquid flow dyeing machine, post-refining may be performed on the fabric using a liquid flow dyeing machine with water.

[0017] (4) Antibacterial treatment process The antibacterial treatment process is a process of applying an antibacterial agent to the fabric treated in the above-described flame-retardant treatment process to add antibacterial performance. Specifically, in the antibacterial treatment process, an antibacterial agent is sprayed onto one side of the fabric (for example, the surface) on which the flame-retardant adhering part is formed by a sprayer and dried at 140 to 180 °C for 5 minutes, thereby forming an antibacterial agent application surface on which the antibacterial agent is applied. In this embodiment, as the antibacterial agent, an inorganic antibacterial agent adjusted to a predetermined concentration is used. In the antibacterial treatment process of this embodiment, for the fabric wound up at a speed of 5.0 m / min, the spray amount is 240 to 350 cc / m 2An antibacterial agent is being sprayed using a sprayer. Also, the antibacterial agent applied in the antibacterial treatment process can not only suppress the growth of bacteria but also suppress the generation / growth of mold. Therefore, the deodorizing performance of preventing odors caused by bacteria and mold can also be added to the fabric through the antibacterial treatment process. Furthermore, the antibacterial agent used in the antibacterial treatment process can contain inorganic catalysts and the like having performances such as deodorization, antiviral, antifouling, antistatic, and decomposition of formaldehyde. Thus, sufficiently high performances can also be added to the fabric through the antibacterial treatment process.

[0018] (5) Water-repellent treatment process The water-repellent treatment process is a process of applying a water-repellent agent to the fabric treated in the above-mentioned antibacterial treatment process to add water-repellent performance. Specifically, in the water-repellent treatment process, after a flame retardant adhering part is formed and an antibacterial agent coating surface is formed on one surface of the fabric, the other surface (for example, the back surface) is sprayed with a fluorine-based water-repellent agent using a sprayer, and dried at 140 to 180 °C for 5 minutes to form a water-repellent agent coating surface on which the water-repellent agent is applied. In this embodiment, as the fluorine-based water-repellent agent, a product of Uniperan ZERO manufactured by Meisei Chemical Industry Co., Ltd. adjusted to a concentration of 0.5% to 2.0% is used. In addition, in the water-repellent treatment process of this embodiment, for the fabric wound up at a speed of 5.0 m / min, the spraying amount is 240 to 350 cc / m 2 A water-repellent agent is being sprayed using a sprayer.

[0019] Next, regarding the interior fabric of the present embodiment described above, an explanation will be given on using a woven fabric in which flame-retardant polyester fibers and non-flame-retardant polyester fibers are interwoven. Generally, since flame-retardant polyester fibers have a flame-retardant function, they are more flame-retardant than non-flame-retardant polyester fibers. However, although flame-retardant polyester fibers subjected to a flameproof treatment are characterized by being difficult to melt with heat, they are highly likely to fail in a flameproof test described below (particularly, a method called the "45° coil method" below). Also, in terms of cost, non-flame-retardant polyester fibers are less expensive than flame-retardant polyester fibers. For these reasons, in an interior fabric composed of polyester fibers, it is preferable to be manufactured using a woven fabric in which flame-retardant polyester fibers and non-flame-retardant polyester fibers are interwoven rather than using a woven fabric composed only of flame-retardant polyester fibers.

[0020] <Performance Tests on the Interior Fabric of the Present Embodiment> Referring to FIGS. 2 to 7, next, for various interior fabrics manufactured by the manufacturing method of the present embodiment described above, a water repellency test which is a performance test of water repellency, a flameproof test which is a performance test of flameproofness, and an antibacterial test which is a performance test of antibacterial and antifouling properties will be described for the results of the tests. FIG. 2 is a diagram showing a table explaining the configurations of various interior fabrics which are the subjects of the water repellency test, the flameproof test, and the antibacterial test, including Examples 1 to 3 which are the interior fabrics of the present embodiment, and Comparative Examples 1 and 2 which are interior fabrics manufactured by a method different from the above-described manufacturing method. FIG. 3 is a diagram showing a table explaining the test results of the water repellency test and the flameproof test performed on Example 1. FIG. 4 is a diagram showing a table explaining the test results of the water repellency test and the flameproof test performed on Example 2. FIG. 5 is a diagram showing a table explaining the test results of the water repellency test and the flameproof test performed on Example 3. FIG. 6 is a diagram showing a table explaining the test results of the water repellency test and the flameproof test performed on Comparative Example 1. FIG. 7 is a diagram showing a table explaining the test results of the water repellency test and the flameproof test performed on Comparative Example 2.

[0021] (1) Water repellency test Here, the water repellency test, which is a performance test for water repellency, will be described. The water repellency test was conducted by the water repellency degree test (spray test) specified in JIS L 1092 (Waterproof test method for textile products). The specific details of the water repellency test are described below. (a) Spray 250 ml of water onto the test specimen (interior fabric 1) tilted at 45°. (b) After dropping excess water droplets, compare the wet state with a comparison sample for judgment. In this case, the initial state and the performance values after washing the test specimen (interior fabric 1) 5 times are indicated by the grades specified in JIS L 1092. (c) As for water repellency, those of grade 3 or higher (grades 3 to 5) are considered qualified.

[0022] (2) Flame retardancy test Here, the flame retardancy test, which is a performance test for flame retardancy, will be described. The flame retardancy test was conducted in accordance with the flame retardancy performance standards for flame retardant articles (basis laws and regulations: Article 4-3, Paragraphs 3 to 7 of the Enforcement Regulations of the Fire Services Act) determined by the Japan Flame Retardant Association, a public interest incorporated foundation. The flame retardancy test of the interior fabric was conducted by a method called the "45° coil method" and a method called the "45° micro burner method". In both the "45° coil method" and the "45° micro burner method", the qualified interior fabric shall meet the flame retardancy performance standards. The specific details of each flame retardancy test are described below.

[0023] ≪45° coil method≫ (a) Test specimens: Prepare 5 test specimens (interior fabrics) with a width of 10 cm and a length such that the mass is 1 (if the length exceeds 20 cm, it shall be less than 1 g but 20 cm). (b) Pretreatment: Use test specimens that have been pretreated either without washing, by washing with water, or by dry cleaning. (c) Conditioning: After 24 hours in a constant temperature dryer at 50 ± 2 °C, for 2 hours or more in a desiccator containing silica gel, or after 1 hour in a constant temperature dryer at 105 ± 2 °C and then for 2 hours or more in a desiccator containing silica gel (d) Combustion method: Hold the test specimen in a coil inclined at 45°, adjust the flame length of the flame contact burner to 45 mm, and bring the flame into contact with the lower end of the test specimen. (e) Evaluation criteria: Those that do not ignite after 3 or more flame contacts are considered qualified.

[0024] ≪45° Microburner Method≫ (a) Test specimen: Use 3 test specimens (interior fabrics) of 35 cm × 25 cm. (b) Pretreatment: Use test specimens that have undergone any one of the following pretreatments: no washing, water washing, or dry cleaning. (c) Conditioning: After 24 hours in a constant temperature dryer at 50 ± 2 °C, for 2 hours or more in a desiccator containing silica gel, or after 1 hour in a constant temperature dryer at 105 ± 2 °C and then for 2 hours or more in a desiccator containing silica gel (d) Combustion method: Hold the test specimen in an inclined state at 45°, adjust the flame length of the flame contact burner to 45 mm, and bring the flame into contact with the lower end of the test specimen for 1 minute. For the ignited test specimen, remove the flame of the flame contact burner 3 seconds after ignition. (e) Evaluation criteria: The afterflame time (the time from when the flame of the flame contact burner is removed until the test specimen stops raising the flame) is 3 seconds or less, the charring time (the time from when the flame of the flame contact burner is removed until the state where the test specimen burns without raising the flame stops) is 5 seconds or less, and the charred area (the area charred until the burning state stops after ignition) is 30 cm 2 Those that satisfy all of the following are considered qualified.

[0025] (3) Antibacterial test Here, the antibacterial test, which is a performance test for antibacterial and odor-proof properties, will be described. The antibacterial test was conducted by the pour plate culture method specified in JIS L 1092:2015 (Bacterial solution absorption method (quantitative test)). In the bacterial solution absorption method, both the target antibacterial processed sample and the standard cloth are inoculated with the bacterial solution and cultured. After a certain period of time under the same conditions, the number of bacteria on the antibacterial processed sample and the standard cloth is measured and compared. The specific content of the antibacterial test is described below. As the test bacterium, Staphylococcus aureus NBRC12732 was used, and as the test bacterial solution, the one with a test bacterium concentration of 1.6×10 5 and with 0.05% of surfactant (Tween80) added was used. (a) Standard cotton cloth was used as the standard cloth, and for the interior fabric as the test sample, the one that had been washed 5 times by the SEK high-temperature accelerated washing method (using JAFET standard compound detergent) was used. (b) The conditions for determining the test validity are as follows: inoculated bacteria concentration (CFU / mL): 1×10 5 ~3×10 5 , growth value [F]: 1.0 or more, maximum-minimum difference (Log) of 3 specimens in the control sample: 1 or less, maximum-minimum difference (Log) of 3 specimens in the test sample: 2 or less. (c) Regarding the antibacterial effect of JIS, those with an antibacterial activity value [A] ≧ 2.0 are considered qualified. (d) Regarding the SEK (abbreviation for Sen-i Evaluation Kino) mark certification criteria, for antibacterial and odor-proof processing: antibacterial activity value [A] ≧ 2.2, for bacteriostatic processing (general use): antibacterial activity value [A] ≧ growth value [F], for bacteriostatic processing (special use): antibacterial activity value [A] > growth value [F], and those meeting these are considered qualified.

[0026] As shown in Fig. 2, first, Example 1, Example 2, Example 3, Comparative Example 1, and Comparative Example 2, which are the subjects of the water repellency test, anti-inflammatory test, and antibacterial test, are interior fabrics with different configurations. The interior fabric of Example 1 is manufactured by the manufacturing method of the present embodiment described above, with 50.0% by weight of flame-retardant polyester fibers and 50.0% by weight of non-flame-retardant polyester fibers, and is subjected to antibacterial treatment on the surface and water repellent treatment on the back. The interior fabric of Example 2 is manufactured by the manufacturing method of the present embodiment described above, with 59.8% by weight of flame-retardant polyester fibers and 40.2% by weight of non-flame-retardant polyester fibers, and is subjected to antibacterial treatment on the surface and water repellent treatment on the back. The interior fabric of Example 3 is manufactured by the manufacturing method of the present embodiment described above, with 75.9% by weight of flame-retardant polyester fibers and 24.1% by weight of non-flame-retardant polyester fibers, and is subjected to antibacterial treatment on the surface and water repellent treatment on the back. The interior fabric of Comparative Example 1 is different from the present embodiment described above. For a fabric with 40.2% by weight of flame-retardant polyester fibers and 59.8% by weight of non-flame-retardant polyester fibers, after applying a flame-retardant treatment to the whole, an antibacterial treatment is applied to the surface and a water repellent treatment is applied to the back. The interior fabric of Comparative Example 2 is manufactured by a method different from the manufacturing method of the present embodiment described above. For a fabric with 59.8% by weight of flame-retardant polyester fibers and 40.2% by weight of non-flame-retardant polyester fibers, after applying a flame-retardant treatment to the whole, an antibacterial treatment and a water repellent treatment are applied to the same surface of the surface.

[0027] As shown in FIG. 3, next, a water repellency test and a flame retardancy test were performed on the interior fabric of Example 1 that had been washed by water and the one that had been dry-cleaned. In Example 1 after water washing, the result of the water repellency test was qualified, and the result of the flame retardancy test was qualified. Also, in Example 1 after dry cleaning, the result of the water repellency test was qualified, and the result of the flame retardancy test was qualified. Generally, in a woven fabric after water washing or dry cleaning, due to the adhesion of trace residues such as components of detergents and solvents and mineral components such as calcium by water washing or dry cleaning, it has been found that the flame retardancy performance is inferior compared to the unwashed one without water washing and dry cleaning. That is, for the woven fabric of Example 1, since the ones after water washing and after dry cleaning passed the flame retardancy test, the ones after water washing and after dry cleaning meet the flame retardancy performance standard, and it is considered that the unwashed one also meets the flame retardancy performance standard. Therefore, the interior fabric of Example 1 has a sufficiently high water repellency performance and also meets the flame retardancy performance standard.

[0028] As shown in FIG. 4, next, a water repellency test and a flame retardancy test were performed on the interior fabric of Example 2 that was unwashed, the one that had been washed by water, and the one that had been dry-cleaned. In the unwashed Example 2, the result of the water repellency test was qualified, and the result of the flame retardancy test was qualified. Also, in Example 2 after water washing, the result of the water repellency test was qualified, and the result of the flame retardancy test was qualified. Furthermore, in Example 2 after dry cleaning, the result of the water repellency test was qualified, and the result of the flame retardancy test was qualified. Therefore, the interior fabric of Example 2 has a sufficiently high water repellency performance and also meets the flame retardancy performance standard.

[0029] As shown in Fig. 5, next, a water repellency test and a flame retardancy test were carried out on the interior fabric of Example 3, including the unwashed one, the one washed by water, and the one dry-cleaned. In the unwashed Example 3, the result of the water repellency test was qualified, and the result of the flame retardancy test was also qualified. Also, in Example 3 after water washing, the result of the water repellency test was qualified, and the result of the flame retardancy test was qualified. Furthermore, even in Example 3 after dry cleaning, the result of the water repellency test was qualified, and the result of the flame retardancy test was qualified. Therefore, the interior fabric of Example 3 has a sufficiently high water repellency performance and also meets the flame retardancy performance standard.

[0030] As shown in Fig. 6, next, a water repellency test and a flame retardancy test were carried out on the interior fabric of Comparative Example 1 for the unwashed one. In the unwashed Comparative Example 1, although the result of the water repellency test was qualified, the results of both the "45° coil method" and the "45° micro burner method" were unqualified, so the result of the flame retardancy test was unqualified. Here, for Comparative Example 1, since the unwashed one was unqualified in the flame retardancy test, it is considered that the unwashed one does not meet the flame retardancy performance, and by extension, the ones after water washing and after dry cleaning also do not meet the flame retardancy performance. Therefore, although the interior fabric of Comparative Example 1 has a sufficiently high water repellency performance, it does not meet the flame retardancy performance standard.

[0031] As shown in FIG. 7, a water repellency test and a flame retardancy test were conducted on the interior fabric of Comparative Example 2, including the unwashed fabric and the fabric after laundering by water washing. In the unwashed Comparative Example 2, although the result of the water repellency test was qualified, the result by the "45° coil method" was unqualified, so the result of the flame retardancy test was unqualified. Also, in Comparative Example 2 after water washing, although the result of the water repellency test was qualified, the result by the "45° micro burner method" was unqualified, so the result of the flame retardancy test was unqualified. Incidentally, the result by the "45° micro burner method" in the flame retardancy test of the unwashed Comparative Example 2 was qualified, and the result by the "45° coil method" in the flame retardancy test of Comparative Example 2 after water washing was qualified. Here, for Comparative Example 2 as well, similar to Comparative Example 1 described above, since the unwashed and the water-washed ones were unqualified in the flame retardancy test, it is considered that the flame retardant performance of the one after dry cleaning does not meet the requirements. Therefore, although the water repellent performance of the interior fabric of Comparative Example 2 is sufficiently high, it does not meet the flame retardancy performance standard.

[0032] Although not shown in FIGS. 3 to 7, when the above-described antibacterial test was conducted on the interior fabrics of Example 1, Example 2, Example 3, Comparative Example 1, and Comparative Example 2, all the interior fabrics passed the JIS antibacterial effect and SEK mark certification standards. Therefore, the interior fabrics of Example 1, Example 2, Example 3, Comparative Example 1, and Comparative Example 2 have sufficiently high antibacterial performance and anti-odor performance.

[0033] <Features of the Interior Fabric of the Present Embodiment> The interior fabric of the present embodiment is a fabric woven with a flame-retardant polyester fiber and a non-flame-retardant polyester fiber, and in the fabric, there is a flame retardant adhering portion where a flame retardant is adhered, on one surface (front surface) of the fabric where the flame retardant adhering portion is formed, there is an antibacterial agent coating surface where an antibacterial agent is applied, and on the other surface (back surface) of the fabric where the flame retardant adhering portion is formed, there is a water repellent coating surface where a water repellent is applied.

[0034] According to the interior fabric of this embodiment, the water repellency performance is sufficiently high, it also meets the flame retardancy performance standard, and furthermore, the antibacterial performance and the odor prevention performance can be made sufficiently high. Specifically, as shown in FIGS. 3 to 5, in the interior fabrics of Example 1, Example 2, and Example 3, which are the interior fabrics of this embodiment, a flame retardant adhering portion is formed over the entire fabric, an antibacterial agent coating surface is formed on the surface, and a water repellent coating surface is formed on the back surface. These interior fabrics meet the flame retardancy performance standard, have a sufficiently high water repellency performance, and furthermore, have a sufficiently high antibacterial performance and odor prevention performance. On the other hand, as shown in FIG. 7, in the interior fabric of Comparative Example 2, in which a flame retardant adhering portion is formed over the entire fabric and both the antibacterial agent and the water repellent are applied to the surface of the fabric, although the water repellency performance, antibacterial performance, and odor prevention performance are sufficiently high, it does not meet the flame retardancy performance standard. Therefore, the interior fabric of this embodiment is different from the case where a flame retardant is adhered over the entire fabric as in Comparative Example 2 and either the antibacterial agent or the water repellent is applied to the same surface. The flame retardancy performance by the flame retardant meets the flame retardancy performance standard, and the water repellency performance by the water repellent, as well as the antibacterial performance and odor prevention performance by the antibacterial agent, can be made sufficiently high.

[0035] In the interior fabric of this embodiment, a water repellent coating surface is formed by applying a water repellent to the back surface of the fabric to make the water repellency performance of the fabric sufficiently high. However, since the water repellent applied to the back surface penetrates into the fibers of the fabric, a sufficiently high water repellency performance can be exhibited even on the surface where the water repellent is not applied. That is, in such an interior fabric of this embodiment, the water repellency performance by the water repellent can be made sufficiently high on both sides (the whole) of the interior fabric. Also, in the case of the antibacterial agent containing an inorganic catalyst or the like having performances such as deodorization, antiviral, antifouling, antistatic, and decomposition of formaldehyde, these performances can also be made sufficiently high for the interior fabric.

[0036] In the interior fabric of the present embodiment, the fabric may be woven with 50.0% to 76.0% by weight of flame-retardant polyester fibers and 24.0% to 50.0% by weight of non-flame-retardant polyester fibers. According to such an interior fabric of the present embodiment, the water-repellent performance is sufficiently high, it conforms to the flame-retardant performance standard, and further, the antibacterial performance and the odor-proof performance can be made sufficiently high. Specifically, as shown in FIGS. 3 to 5, in each of the interior fabrics of Example 1, Example 2, and Example 3, which are interior fabrics of the present embodiment and are made of a fabric in which 50.0% to 76.0% by weight of flame-retardant polyester fibers and 24.0% to 50.0% by weight of non-flame-retardant polyester fibers are woven, they conform to the flame-retardant performance standard, have sufficiently high water-repellent performance, and further, have sufficiently high antibacterial performance and odor-proof performance. On the other hand, as shown in FIG. 6, in the interior fabric of Comparative Example 1, which is made of a fabric in which 40.2% by weight of flame-retardant polyester fibers and 59.8% by weight of non-flame-retardant polyester fibers are woven, although the water-repellent performance, antibacterial performance, and odor-proof performance are sufficiently high, it does not conform to the flame-retardant performance standard. Therefore, for such an interior fabric of the present embodiment, unlike Comparative Example 1 where the content of flame-retardant polyester fibers is less than 50.0% by weight, the flame-retardant performance by the flame retardant conforms to the flame-retardant performance standard, and the water-repellent performance by the water repellent, as well as the antibacterial performance and odor-proof performance by the antibacterial agent, can be made sufficiently high.

[0037] In the manufacturing method of the interior fabric of the present embodiment, it is a manufacturing method of an interior fabric made of a fabric in which flame-retardant polyester fibers and non-flame-retardant polyester fibers are woven, and it is characterized by performing a flame-retardant treatment of applying a flame retardant on one surface and the other surface of the fabric, an antibacterial treatment of applying an antibacterial agent on one surface of the fabric subjected to the flame-retardant treatment, and a water-repellent treatment of applying a water repellent on the other surface of the fabric subjected to the flame-retardant treatment.

[0038] Here, the conventional antibacterial treatment and water repellent treatment will be described. In the conventional method for manufacturing interior fabrics, in the antibacterial treatment, a padding treatment is performed to impregnate the fabric with an antibacterial agent by immersing the fabric in a solution containing the antibacterial agent at a predetermined concentration. Similarly, in the water repellent treatment, a padding treatment using a solution of a water repellent at a predetermined concentration is performed. That is, in such a conventional method for manufacturing interior fabrics, the antibacterial treatment and the water repellent treatment are applied to the entire fabric (both sides). In this regard, according to the method for manufacturing interior fabrics of the present embodiment, after a flame retardant treatment is applied to the entire fabric (both sides), an antibacterial agent-coated surface is formed on the front surface, and a water repellent agent-coated surface is formed on the back surface. Therefore, with such a method for manufacturing interior fabrics of the present embodiment, as described above, the flame retardant performance by the flame retardant agent meets the flame retardant performance standard, and the water repellent performance by the water repellent agent, the antibacterial performance by the antibacterial agent, and the anti-odor performance are also high enough to manufacture interior fabrics.

[0039] In the method for manufacturing interior fabrics of the present embodiment, a water repellent agent is sprayed on the back surface of the fabric in the water repellent treatment step to form a water repellent agent-coated surface, making the water repellent performance sufficiently high. However, since the water repellent agent sprayed on the back surface penetrates into the fibers of the fabric, a sufficiently high water repellent performance can be exhibited even on the front surface where the water repellent agent is not sprayed. That is, with such a method for manufacturing interior fabrics of the present embodiment, a sufficiently high water repellent performance by the water repellent agent can be manufactured on both sides (the entire surface) of the interior fabric. Also, in the antibacterial agent in the antibacterial treatment step, when an inorganic catalyst or the like having performances such as deodorization, antiviral, antifouling, antistatic, and decomposition of formaldehyde is contained, interior fabrics with sufficiently high these performances can be manufactured.

[0040] In the method for manufacturing the interior fabric of the present embodiment, for the antibacterial treatment, the antibacterial agent may be applied by spraying the antibacterial agent onto one surface of the fabric that has been subjected to the flame-retardant treatment. For the water-repellent treatment, the water-repellent agent may be applied by spraying the water-repellent agent onto the other surface of the fabric that has been subjected to the flame-retardant treatment. According to such a method for manufacturing the interior fabric, for example, after the entire fabric (both sides) has been subjected to the flame-retardant treatment, an appropriate amount of the antibacterial agent is applied to the surface, and an appropriate amount of the water-repellent agent is applied to the back surface, and such a product can be easily manufactured.

[0041] In the method for manufacturing the interior fabric of the present embodiment, the fabric may be woven with 50.0% by weight to 76.0% by weight of flame-retardant polyester fibers and 24.0% by weight to 50.0% by weight of non-flame-retardant polyester fibers. With such a method for manufacturing the interior fabric, as described above, the flame-retardant performance by the flame-retardant agent meets the flame-retardant performance standard, and the water-repellent performance by the water-repellent agent, as well as the antibacterial performance and the anti-odor performance by the antibacterial agent, can all be made sufficiently high.

[0042] [Other Embodiments] In the above embodiment, a fabric produced in the weaving process with the flame-retardant polyester fibers as the warp and the non-flame-retardant polyester fibers as the weft was used. However, these can be reversed, that is, the flame-retardant polyester fibers can be used as the weft and the non-flame-retardant polyester fibers can be used as the warp for weaving. Furthermore, a fabric produced in the weaving process with a mixture of flame-retardant polyester fibers and non-flame-retardant polyester fibers in a predetermined ratio (for example, a ratio of 1:1 may also be acceptable) as the warp and a mixture of flame-retardant polyester fibers and non-flame-retardant polyester fibers in a predetermined ratio (for example, a ratio of 1:1 may also be acceptable) as the weft may be used. Even for interior fabrics made of such fabrics, as long as 50.0% by weight to 76.0% by weight of flame-retardant polyester fibers and 24.0% by weight to 50.0% by weight of non-flame-retardant polyester fibers are used, the water-repellent performance is sufficiently high, it meets the flame-retardant performance standard, and furthermore, the antibacterial performance and the anti-odor performance can be made sufficiently high.

[0043] In the above-described embodiment, in the flame-retardant treatment step, flame-retardant processing with a flame retardant was performed by the liquid flow dyeing method. However, any method may be used as long as flame-retardant processing using a flame retardant can be performed. For example, in the flame-retardant treatment step, after immersing the fabric in a padding bath of the flame retardant, squeezing it with a mangle to remove the excess flame retardant, and then performing heat treatment at a temperature of 180 to 190°C, a flame-retardant adhering portion, which is a portion where the flame retardant is adhered to the fibers of the fabric, may be formed over the entire fabric. In addition, as such a flame retardant in the flame-retardant treatment step, Nonnen (registered trademark) R031-5 of Marubishi Oil Chemical Co., Ltd. may be used as a phosphorus-based flame retardant. Even in the flame-retardant treatment step by such a method, similar to the case where the flame-retardant treatment by the liquid flow dyeing method of the above-described embodiment is performed, the flame-retardant performance by the flame retardant conforms to the flame-retardant performance standard, and the water-repellent performance by the water-repellent agent, as well as the antibacterial performance and the anti-odor performance by the antibacterial agent, are all sufficiently high, and an interior fabric can be manufactured. In addition, in such a flame-retardant treatment step, after the flame retardant is adhered to the fabric using the padding bath of the flame retardant, post-scouring may be performed on the fabric using an open soaper using water or a liquid flow dyeing machine using water.

[0044] In the manufacturing method of the above-described embodiment, the pre-refining step was executed before the flame-retardant treatment step. However, the flame-retardant treatment step may be executed without performing the pre-refining step. Specifically, in the case of the flame-retardant treatment in the liquid-flow dyeing method, the fabric that has not undergone the pre-refining step may be subjected to the flame-retardant treatment by a liquid-flow dyeing machine, and then post-refining may be performed by a liquid-flow dyeing machine using water. Also, in the case of the flame-retardant treatment using a pad bath of a flame retardant, the fabric that has not undergone the pre-refining step may be subjected to the flame-retardant treatment using a pad bath, and then post-refining may be performed by an open soaper using water or a liquid-flow dyeing machine using water. Further, in the manufacturing method of the above-described embodiment, after the flame-retardant treatment step, the antibacterial treatment step was executed, and then the water-repellent treatment step was executed in that order. However, after the flame-retardant treatment step, the water-repellent treatment step may be executed, and then the antibacterial treatment step may be executed in that order. Even with the flame-retardant treatment by such methods, similar to the manufacturing method of the above-described embodiment, the flame-retardant performance by the flame retardant conforms to the flame-retardant performance standard, and the water-repellent performance by the water repellent, as well as the antibacterial performance and the anti-odor performance by the antibacterial agent, are all sufficiently high, and an interior fabric can be manufactured.

[0045] In the above-described embodiment, regarding the application of the antibacterial agent in the antibacterial treatment step and the application of the water repellent in the water-repellent treatment step, a sprayer was used to apply to each surface of the fabric. However, any method that can apply to each surface of the fabric may be used. Specifically, for example, something like a brush or a roller may be used to apply the antibacterial agent or the water repellent to each surface of the fabric.

[0046] As described above, the present invention has been described based on the embodiments and the modified examples. However, the above-described embodiments of the invention are for facilitating the understanding of the present invention and do not limit the present invention. The present invention can be changed and improved without departing from its gist and the scope of the claims, and equivalents of the present invention are included therein.

Claims

1. A fabric woven from a flame-retardant polyester fiber and a non-flame-retardant polyester fiber, in the fabric, a flame retardant adhering portion which is a portion where a flame retardant is adhered, one surface of the fabric on which the flame retardant adhering portion is formed, and an antibacterial agent coating surface on which an antibacterial agent is applied, the other surface of the fabric on which the flame retardant adhering portion is formed, and a water repellent coating surface on which a water repellent is applied, An interior fabric characterized by comprising these.

2. In the interior fabric according to Claim 1, the fabric is characterized in that 50.0% by weight to 76.0% by weight of the flame-retardant polyester fiber and 24.0% by weight to 50.0% by weight of the non-flame-retardant polyester fiber are woven together.

3. A method for manufacturing an interior fabric made of a fabric woven from a flame-retardant polyester fiber and a non-flame-retardant polyester fiber, a flame retardant treatment for applying a flame retardant to one surface and the other surface of the fabric, an antibacterial treatment for applying an antibacterial agent to one surface of the fabric subjected to the flame retardant treatment, a water repellent treatment for applying a water repellent to the other surface of the fabric subjected to the flame retardant treatment, A method for manufacturing an interior fabric characterized by performing these.

4. In the method for manufacturing an interior fabric according to Claim 3, the antibacterial treatment is characterized in that the antibacterial agent is applied by spraying the antibacterial agent onto one surface of the fabric subjected to the flame retardant treatment.

5. In the method for manufacturing an interior fabric according to Claim 3, the water repellent treatment is characterized in that the water repellent is applied by spraying the water repellent onto the other surface of the fabric subjected to the flame retardant treatment.

6. In the method for manufacturing an interior fabric according to Claim 3, the fabric is characterized in that it is woven from 50.0% by weight to 76.0% by weight of the flame-retardant polyester fiber and 24.0% by weight to 50.0% by weight of the non-flame-retardant polyester fiber.

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