Woven fabric and textile product

Abstract

To provide a woven fabric having excellent flame retardancy as well as reversible improvement in breathability due to perspiration and having good appearance quality, and a textile product using the woven fabric.SOLUTION: A woven fabric comprising a spun yarn containing a flame-retardant fiber and a composite yarn including a filament yarn made of a composite fiber in which a polyester component and a polyamide component are bonded in a side-by-side type or an eccentric core-sheath type, in the woven fabric, a difference between an air permeability before moisture absorption measured by JIS L 1096-2010 8.26.1 Method A (Fragile-type air permeability tester) after leaving in an atmosphere of a temperature of 20°C and humidity of 65% RH for 24 hours, and an air permeability after moisture absorption measured by JIS L 1096-2010 8.26.1 Method A (Fragile-type air permeability tester) after leaving in an atmosphere of a temperature of 20°C and humidity of 80% RH for 24 hours (air permeability after moisture absorption - air permeability before moisture absorption) is 5 cc / cm2 / sec or more, a limiting oxygen index according to JIS K7201:1999 after washing five times according to the JIS L1930:C4M method is 28 or more, and a fabric weight is 240 g / m2 or less.SELECTED DRAWING: None

Description

[Technical Field]

[0001] The present invention relates to a woven fabric which not only has excellent flame retardancy but also exhibits breathability that is reversibly improved by perspiration and has a good appearance, and to a textile product made using said woven fabric. [Background technology]

[0002] Flame-retardant fabrics have traditionally been used in workwear worn by firefighters, electric power and chemical workers, and other workers who are exposed to flames. These flame-retardant fabrics primarily use flame-retardant fibers, such as meta-type wholly aromatic polyamide fibers and para-type wholly aromatic polyamide fibers, and are generally considered difficult to make breathable. Prolonged exposure to flames and sweating from the skin can cause stuffiness and stickiness, resulting in reduced comfort.

[0003] As a method for eliminating stuffiness and stickiness caused by sweating, for example, a breathable self-regulating fabric using a composite long fiber in which a polyester component and a polyamide component are bonded side-by-side has been proposed (for example, Patent Documents 1, 2, and 3). However, although such fabrics have reversible improvements in breathability when wet compared to when dry, there are problems in that the dimensions of the fabric change significantly when wet, and it is difficult to ensure flame retardancy. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Japanese Patent Application Laid-Open No. 2006-97147 [Patent Document 2] Japanese Patent Application Laid-Open No. 2006-97176 [Patent Document 3] Japanese Patent Application Laid-Open No. 2009-228141 Summary of the Invention [Problem to be solved by the invention]

[0005] The present invention has been made in view of the above-mentioned background, and an object of the present invention is to provide a woven fabric which not only has excellent flame retardancy but also has breathability which is reversibly improved by perspiration and which has a good appearance quality, and a textile product made using the woven fabric. [Means for solving the problem]

[0006] The present inventors have conducted extensive research to achieve the above object and have completed the present invention. Thus, the present invention provides the following.

[0007] 1. A woven fabric comprising a composite yarn containing a spun yarn containing a flame-retardant fiber and a yarn consisting of composite fibers in which a polyester component and a polyamide component are bonded side-by-side or eccentric core-sheath configuration, wherein the woven fabric is left in an atmosphere at a temperature of 20°C and a humidity of 65% RH for 24 hours, and the difference between the air permeability before moisture absorption measured according to JIS L 1096-2010 8.26.1 Method A (Fragile type air permeability tester) and the air permeability after moisture absorption measured according to JIS L 1096-2010 8.26.1 Method A (Fragile type air permeability tester) after the woven fabric is left in an atmosphere at a temperature of 20°C and a humidity of 80% RH for 24 hours (air permeability after moisture absorption - air permeability before moisture absorption) is 5 cc / cm 2 / sec or more, and the limiting oxygen index in JIS K7201:1999 after washing five times in the JIS L1930:C4M method is 28 or more, and the fabric weight is 240 g / m 2 A woven fabric characterized by: 2. The woven fabric according to 1 above, wherein the flame-retardant fiber is one or more fibers selected from the group consisting of meta-type wholly aromatic polyamide fiber, para-type wholly aromatic polyamide fiber, polyparaphenylenebenzoxazole fiber, polybenzimidazole fiber, polyimide fiber, polyetherimide fiber, polyamideimide fiber, carbon fiber, polyphenylene sulfide fiber, polyvinyl chloride fiber, flame-retardant rayon, modacrylic fiber, flame-retardant acrylic fiber, flame-retardant polyester fiber, flame-retardant vinylon fiber, melamine fiber, fluorine fiber, flame-retardant wool, and flame-retardant cotton. 3. The woven fabric according to 1 or 2 above, wherein the composite yarn is a yarn obtained by plying and twisting the spun yarn having a British cotton count of 10 to 120 with a yarn made of the composite fiber. 4. A woven fabric according to any one of 1 to 3 above, wherein the weight ratio of the flame-retardant fiber in the woven fabric is within the range of 65 to 84% by weight of the woven fabric, and the weight ratio of the composite fiber in the range of 16 to 35% by weight of the woven fabric. 5. The woven fabric according to any one of the above items 1 to 4, wherein the yarn made of the conjugated fiber is a multifilament having a single fiber fineness of 0.5 to 10.0 dtex and a total fineness of 20 to 200 dtex. 6. A textile product made using the woven fabric according to any one of the above items 1 to 5, and selected from the group consisting of firefighting clothing, fire-resistant clothing, office uniforms, racing suits for motorsports, work clothes, gloves, hats, vests, seats, tents, membrane materials, hoods, building materials, housing materials, and vehicle interior materials. [Effects of the Invention]

[0008] According to the present invention, a woven fabric having excellent flame retardancy as well as breathability that is reversibly improved by perspiration and has a good appearance quality can be obtained, and a textile product using the woven fabric can be obtained. DETAILED DESCRIPTION OF THE INVENTION

[0009] Hereinafter, embodiments of the present invention will be described in detail. First, the present invention is a woven fabric made using a composite yarn including a spun yarn containing a flame-retardant fiber and a yarn made of a composite fiber in which a polyester component and a polyamide component are bonded in a side-by-side or eccentric core-sheath configuration.

[0010] Examples of the flame-retardant fibers include meta-type wholly aromatic polyamide fibers (meta-type aramid fibers), para-type wholly aromatic polyamide fibers (para-type aramid fibers), polyparaphenylenebenzoxazole fibers, polybenzimidazole fibers, polyimide fibers, polyetherimide fibers, polyamideimide fibers, carbon fibers, polyphenylene sulfide fibers, polyvinyl chloride fibers, flame-retardant rayon, modacrylic fibers, flame-retardant acrylic fibers, flame-retardant polyester fibers, flame-retardant vinylon fibers, melamine fibers, fluorine fibers, flame-retardant wool, and flame-retardant cotton. One or more of these flame-retardant fibers can be used.

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

[0012] From the viewpoint of use in clothing applications where superior flame retardancy is required, it is useful for these flame-retardant fibers to contain a flame retardant. As the flame retardant, phosphorus-based flame retardants are preferred, and tris(chloropropyl)phosphate is particularly preferred. The flame-retardant fiber preferably has a limiting oxygen index of 23 or more, more preferably 24 or more, and particularly preferably 25 or more, as measured in accordance with JIS K7201.

[0013] These flame-retardant fibers may contain additives such as antioxidants, ultraviolet absorbers, heat stabilizers, titanium oxide, colorants, inert fine particles, etc., within the scope of the object of the present invention. The flame-retardant fibers preferably have a fiber length in the range of 35 to 110 mm. The total fineness of the spun yarn may be appropriately selected depending on the application, taking into consideration surface appearance, heat resistance, heat protection, stretchability, texture, etc., and the thickness of the spun yarn is particularly preferably in the range of 10 to 120 British cotton count.

[0014] The single fiber fineness of the spun yarn is preferably in the range of 0.6 to 5.5 dtex from the viewpoint of good spinning processability and use in clothing applications where softness is required. In the present invention, the composite fiber is composed of a polyester component and a polyamide component, and the two components are bonded together in a side-by-side or eccentric core-sheath configuration.

[0015] Here, preferred examples of the polyester component include modified polyesters such as polyethylene terephthalate, polytrimethylene terephthalate, polypropylene terephthalate, and polybutylene terephthalate, which are copolymerized with a compound having an alkali metal or alkaline earth metal sulfonic acid or a phosphonium salt and one or more functional groups capable of forming an ester, in terms of bonding with the other polyamide component. Among these, modified polyethylene terephthalate, in which the above-mentioned compound is copolymerized, is particularly preferred in terms of versatility and polymer cost. Examples of copolymerization components include 5-sodium sulfoisophthalic acid and its ester derivatives, 5-phosphonium sulfoisophthalic acid and its ester derivatives, and sodium p-hydroxyethoxybenzenesulfonate. Of these, 5-sodium sulfoisophthalic acid is preferred. The copolymerization amount is preferably in the range of 2.0 to 4.5 mol %. If the copolymerization amount is less than 2.0 mol %, excellent crimping performance can be obtained, but peeling may occur at the bonding interface between the polyamide component and the polyester component. Conversely, if the copolymerization amount is greater than 4.5 mol%, crystallization of the polyester component becomes difficult during stretching heat treatment, so the stretching heat treatment temperature must be increased, which may result in frequent yarn breakage.

[0016] On the other hand, the polyamide component is not particularly limited as long as it has an amide bond in the main chain, and examples thereof include nylon-4, nylon-6, nylon-66, nylon-46, nylon-12, etc. Among them, nylon-6 and nylon-66 are preferred in terms of versatility, polymer cost, and spinning stability.

[0017] The polyester component and / or polyamide component may contain various additives such as pigments, matting agents, antifouling agents, fluorescent brighteners, flame retardants, stabilizers, antistatic agents, light-resistant agents, and ultraviolet absorbers.

[0018] The side-by-side or eccentric sheath-core composite fibers may be, for example, composite fibers having a semicircular cross section as shown in (A) and (B) of Figure 1 in JP-A 2006-112009, or an eccentric sheath-core composite fiber as shown in (C) of JP-A 2006-112009. Furthermore, they may be triangular or rectangular, or may have a hollow section within their cross section. Of these, the shape shown in (A) above, in which two components are bonded together in a semicircular shape, resulting in a round fiber, is preferred. The composite ratio of the two components can be selected arbitrarily, but typically, the weight ratio of the polyester component to the polyamide component (polyester component:polyamide component) is preferably within the range of 30:70 to 70:30 (more preferably 40:60 to 60:40).

[0019] In order to reversibly improve the breathability of the fabric when wet compared to when dry and to prevent deterioration of the texture of the fabric, the composite fiber is preferably a multifilament having a single fiber fineness of 0.5 to 10.0 dtex (more preferably 0.8 to 5 dtex) and a total fineness of 20 to 200 dtex.

[0020] Such a conjugated fiber in which different polymers are bonded side-by-side or eccentrically in sheath-core configuration has latent crimping properties, which are manifested when subjected to heat treatment such as dyeing, as described below. As for the crimp structure, it is preferable that the polyamide component is located on the inside of the crimp and the polyester component is located on the outside of the crimp.

[0021] When a composite fiber has such a crimped structure, the inner polyamide component swells and expands while the outer polyester component undergoes almost no change in length when wet, resulting in a decrease in the crimp percentage (the apparent length of the composite fiber increases).On the other hand, when dry, the inner polyamide component shrinks while the outer polyester component undergoes almost no change in length, resulting in an increase in the crimp percentage (the apparent length of the composite fiber decreases).

[0022] In the composite yarn of the present invention, the composite fiber and the other fibers are preferably contained in a ratio of (composite fiber:fiber other than the composite fiber) of 10:90 to 90:10 (preferably 25:75 to 75:25), and the total fineness is preferably in the range of 200 to 600 dtex.

[0023] If the content of the composite fiber is less than the above range, the breathability may not be improved effectively when wet, which is undesirable, whereas if the content of the composite fiber is more than the above range, the flame retardancy may be reduced.

[0024] The composite yarn is preferably a plied / twisted yarn. More specifically, the spun yarn and the composite fiber are preferably plied / twisted using a commercially available up-twister, Italian twister, double twister, or the like.

[0025] Twist setting may be performed depending on the required quality. The composite plied yarn can be twist set using vacuum steam setting, which is used for setting ordinary spun yarn. The temperature during setting of the composite plied yarn is preferably in the range of 50 to 95°C (more preferably 50 to 85°C). If the twist setting temperature of the composite plied yarn is too high, the stretchability of the final fabric may be impaired.

[0026] Next, the woven fabric of the present invention can be produced by weaving the composite yarn in a conventional manner. In order to achieve both excellent flame retardancy and improved breathability upon moisture absorption, it is preferable that the weight ratio of the flame-retardant fiber in the woven fabric is within the range of 65 to 84% by weight and the weight ratio of the composite fiber is within the range of 16 to 35% by weight. If the weight ratio of the flame-retardant fiber is less than this range, flame retardancy may be reduced. Also, if the weight ratio of the composite fiber is less than this range, breathability upon moisture absorption may not be significantly improved.

[0027] Examples of the weave of the woven fabric include plain weave, twill weave, and satin weave, and plain weave, 2 / 1 twill, and 2 / 2 twill weave are preferred. Weaves with more floats than this have a high stretchability but may have poor anti-pilling properties.

[0028] It is preferable to subject such woven fabrics to heat treatments such as scouring, relaxation, dyeing, setting, etc. Subsequently, various types of processing may be additionally applied to impart functions such as water absorption, water repellency, raising, flame retardancy, UV protection, antibacterial properties, deodorizing agents, insect repellents, luminous agents, retroreflective agents, and negative ion generators.

[0029] In the woven fabric thus obtained, the composite fibers contained in the fabric effectively shrink when wet, resulting in a longer apparent yarn length. Meanwhile, the fibers other than the composite fibers that make up the composite yarn do not increase in length. As a result, the composite yarn increases voids in the spun yarn without significantly changing its length, improving the breathability of the fabric. Meanwhile, the crimp percentage of the composite fibers increases when dry, shortening the apparent yarn length of the composite fibers. As a result, the voids in the composite yarn become smaller, reducing the breathability of the fabric. These effects make it possible to reversibly improve the breathability of the fabric when wet compared to when dry, without significantly changing the dimensions of the fabric when wet.

[0030] The air permeability before and after moisture absorption is determined by leaving a woven fabric in an atmosphere of 20°C temperature and 65% RH for 24 hours, and then measuring the air permeability before moisture absorption (air permeability in a dry state) according to JIS L 1096-2010 8.26.1 A method (Fragile type air permeability tester method) and the difference between the air permeability after moisture absorption, measured according to JIS L 1096-2010 8.26.1 A method (Fragile type air permeability tester method) after leaving the dried woven fabric in an atmosphere of 20°C temperature and 80% RH for 24 hours, in other words, the difference between the air permeability after moisture absorption and the air permeability before moisture absorption is 5cc / cm 2 / sec or more (preferably 5-15cc / cm 2 / sec).

[0031] It is also important that the limiting oxygen index according to JIS K7201:1999 after washing five times according to the JIS L1930:C4M method is 28 or more (more preferably 28 to 35). In addition, the fabric is lightweight with a basis weight of 240g / m 2 or less (more preferably 160 to 230 g / m 2 ) is important.

[0032] Next, the textile products of the present invention are made using the above-described woven fabric. Because such textile products use the above-described woven fabric, they have not only flame retardancy but also excellent breathability (heat retention). Examples of such textile products include firefighting uniforms, fire-resistant uniforms, office uniforms, racing suits for motorsports, workwear, gloves, hats, vests, and various industrial materials (sheets, tents, membrane materials, hoods, building materials, housing materials, vehicle interior materials, etc.). Examples of such workwear include workwear for steel mills and iron and steel plants, welding workwear, and workwear for explosion-proof areas. Examples of such gloves include work gloves used in industries that handle precision parts, such as the aircraft industry, the information equipment industry, and the precision equipment industry. [Example]

[0033] Examples and comparative examples of the present invention will now be described in detail, but the present invention is not limited to these. The measurement items in the examples were measured by the following methods.

[0034] (1) Flame retardancy The limiting oxygen index (LOI) was measured according to JIS K7201:1999 (combustibility test method for polymeric materials using the oxygen index method) and used as an index of flame retardancy. The garment was washed five times according to the JIS L1930:C4M method, and then dried, after which the LOI was measured.

[0035] (2) Air permeability before and after moisture absorption The air permeability before moisture absorption (dry air permeability) was measured by leaving the woven fabric in an atmosphere at 20°C and 65%RH for 24 hours, and then measuring the air permeability using JIS L 1096-1998, 6.27.1, Method A (Fragile air permeability tester method). The air permeability after moisture absorption was measured by leaving the yarn in an atmosphere at 20°C and 80%RH for 24 hours, and then measuring the air permeability again using JIS L 1096-1998, 6.27.1, Method A (Fragile air permeability tester method). From these measured values, the air permeability in the dry state, the air permeability after moisture absorption, and the difference in air permeability between the moisture-absorbed and dry states were calculated.

[0036] (3) Weight The basis weight was measured according to JIS L 1096-2010 8.3.

[0037] [Example 1] A meta-type wholly aromatic polyamide fiber (manufactured by Teijin Limited, trade name "Teijinconex"), single fiber fineness 1.7 dtex, fiber length 51 mm) and a para-type wholly aromatic polyamide fiber (manufactured by Teijin Limited, trade name "Technora", single fiber fineness 1.7 dtex, fiber length 51 mm) were used to produce a spun yarn with a British cotton count of 40 / 1 (fineness 147.6 dtex) with a twist of 28.6 turns / 2.54 cm (twist direction Z) so that the mixture was 95% by weight of meta-type wholly aromatic polyamide fiber and 5% by weight of para-type wholly aromatic polyamide fiber. Two of the spun yarns were then combined together to produce a two-ply twisted yarn with a twist of 27.0 turns / 2.54 cm (twist direction S).

[0038] Next, a two-ply twisted yarn was obtained using a composite fiber (manufactured by Teijin Frontier Co., Ltd., product name "Fiberlive", total fineness 84 dtex / 24 strands) in which a polyester component and a polyamide component were bonded side-by-side, and the above two-ply twisted yarn with a twist count of 19.0 turns / 2.54 cm (twist direction S). The two-ply twisted yarn was then twist-set in a vacuum steam setting machine at a setting temperature of 120°C for a setting time of 20 minutes to obtain a composite yarn.

[0039] Next, using the composite yarn as the warp and weft, a plain weave fabric was woven with a warp density of 62 threads / 2.54 cm and a weft density of 52 threads / 2.54 cm. The resulting unprocessed fabric (grey) was singed and scoured by conventional methods, and then subjected to a finishing heat setting to obtain a woven fabric. The resulting fabric had a warp density of 62 threads / 2.54 cm, a weft density of 53 threads / 2.54 cm, a limiting oxygen index (LOI) of 29, and a dry air permeability of 7 cc / cm. 2 / sec, and the air permeability after absorbing moisture is 13cc / cm 2 The evaluation results are shown in Table 1.

[0040] [Examples 2 to 5] The same procedures were carried out as in Example 1 except that the density of the woven fabric was changed. The evaluation results are shown in Table 1.

[0041] [Comparative Example 1] The same procedure was followed as in Example 1, except that a spun yarn not containing composite fibers was used. The evaluation results are shown in Table 1.

[0042] Comparative Example 2 The procedure was the same as in Example 1, except that a double-twisted yarn of spun yarn and PET (polyethylene terephthalate fiber) was used. The evaluation results are shown in Table 1.

[0043] Comparative Example 3 The same procedures were carried out as in Example 1, except that a double-twisted yarn of spun yarn and nylon was used. The evaluation results are shown in Table 1.

[0044] [Table 1] [Industrial Applicability]

[0045] According to the present invention, a woven fabric having excellent flame retardancy as well as breathability that is reversibly improved by perspiration and has a good appearance quality, and a textile product using the woven fabric are provided, and the industrial value of the fabric is extremely great.

Claims

1. A woven fabric comprising a composite yarn including a spun yarn containing a flame-retardant fiber and a yarn made of a composite fiber in which a polyester component and a polyamide component are bonded in a side-by-side or eccentric core-sheath configuration, The woven fabric was left in an atmosphere of 20°C and 65% RH for 24 hours, and then the difference between the air permeability before moisture absorption measured according to JIS L 1096-2010 8.26.1 Method A (Fragile-type air permeability tester method) and the air permeability after moisture absorption measured according to JIS L 1096-2010 8.26.1 Method A (Fragile-type air permeability tester method) after the woven fabric was left in an atmosphere of 20°C and 80% RH for 24 hours (air permeability after moisture absorption - air permeability before moisture absorption) was 5 cc / cm ２ / sec or more, the limiting oxygen index according to JIS K7201:1999 after washing five times according to the JIS L1930:C4M method is 28 or more, and the basis weight of the woven fabric is 240 g / m ２ A woven fabric characterized by:

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

3. 2. The woven fabric according to claim 1, wherein the composite yarn is a yarn obtained by plying and twisting the spun yarn having a British cotton count of 10 to 120 and a yarn made of the composite fiber.

4. 2. The woven fabric according to claim 1, wherein the weight ratio of the flame-retardant fiber is in the range of 65 to 84% by weight of the woven fabric, and the weight ratio of the composite fiber is in the range of 16 to 35% by weight of the woven fabric.

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

6. A textile product made using the woven fabric according to any one of claims 1 to 5, which is selected from the group consisting of firefighting suits, fire-resistant suits, office uniforms, racing suits for motorsports, work clothes, gloves, hats, vests, seats, tents, membrane materials, hoods, building materials, housing materials, and vehicle interior materials.

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