Flame-retardant recycled bundle-spun yarn, flame-retardant recycled fabric and preparation method therefor

Abstract

To provide a flame-retardant recycled bundled spun yarn using a flame-retardant recycled fiber, to provide a flame-retardant recycled woven fabric using the same, and to provide a method for producing the same.SOLUTION: After the flame-retardant recycled bundle-spun yarn is obtained by using the flame-retardant recycled fiber to which the oil agent is applied, a woven fabric is produced if necessary.SELECTED DRAWING: None

Description

[Technical Field]

[0001] The present invention relates to a flame-retardant recycled spun yarn using flame-retardant recycled fibers, a flame-retardant recycled fabric using the same, and a method for producing the same. [Background technology]

[0002] Flame-retardant fabrics containing flame-retardant fibers such as fully aromatic polyamide fibers have traditionally been used as workwear for firefighters, electric power companies, and chemical companies, where workers are exposed to flames due to their excellent heat and flame resistance. Although flame-retardant fabrics use flame-retardant fibers with excellent properties, their performance deteriorates with use, and they become unusable due to staining, rubbing, tearing, fraying, and ultimately end up being discarded. Furthermore, scraps are generated at each stage of the production of flame-retardant fabrics and when workwear is sewn using these fabrics. As a result, scraps and used products generated at each process are generated as waste. Most of these process scraps and used products are used for industrial purposes, and unlike commonly used products, they are rarely reused; most are incinerated or disposed of in landfills.

[0003] On the other hand, in recent years, there has been a demand to reduce resource consumption and reduce the burden on the environment. Specifically, in the textile industry, used general-purpose textile products, so-called waste fibers such as rags and waste fibers from used clothing, are reused. For example, in the wool recycling market, the waste fibers are used as material recycling materials and processed into cotton or yarn to make textile products such as felt and work gloves.

[0004] Similarly, there is a demand for applying the same recycling methods to waste materials from each process and used products of flame-retardant fabrics as to general-purpose fiber products (for example, Patent Documents 1 and 2). However, flame-retardant fabrics have superior heat resistance and flame retardancy compared to fabrics made of general-purpose fibers, and also have high tensile strength and cut resistance. Therefore, when a known fiber spreader is used under conventional conditions, problems arise, making it difficult to spread the fibers efficiently and sufficiently.

[0005] Furthermore, recycled fibers obtained by opening woven fabrics have short fiber lengths, making it difficult to utilize such fibers and turn them into high-value-added products. When short-fiber blends are spun, there are problems such as poor processability, frequent yarn breakage, and fuzziness, making it difficult to form into spun yarn. [Prior art documents] [Patent documents]

[0006] [Patent Document 1] Japanese Patent Application Laid-Open No. 2006-233409 [Patent Document 2] Japanese Patent Application Laid-Open No. 2005-105491 Summary of the Invention [Problem to be solved by the invention]

[0007] The present invention aims to provide a flame-retardant recycled spun yarn and a flame-retardant recycled fabric that have improved openability of recycled fibers and good quality in appearance, fluff, etc., and a method for producing the same. [Means for solving the problem]

[0008] The present inventors have conducted extensive research to achieve the above object and have completed the present invention. Thus, the following inventions are provided.

[0009] 1. A flame-retardant recycled bundled spun yarn, characterized in that it contains flame-retardant recycled fibers to which an oil agent has been applied. 2. The flame-retardant recycled spun yarn described in 1 above, wherein the oil agent contains a silicone-based component. 3. The flame-retardant recycled spun yarn according to 1 or 2 above, wherein the amount of the oil applied is 0.2 to 1.0% by weight based on the weight of the flame-retardant recycled fiber. 4. The flame-retardant recycled shim spun yarn according to any one of 1 to 3 above, wherein the number of crimps in the flame-retardant recycled fiber measured according to JIS L1015:2010 is 1.0 crimp / 2.54 cm or less. 5. The flame-retardant recycled bundled spun yarn according to any one of 1 to 4 above, wherein the flame-retardant recycled fiber is one or more fibers selected from the group consisting of meta-aramid fiber, para-aramid 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. 6. The flame-retardant recycled spun yarn according to any one of 1 to 5, The internal fibers of the flame-retardant recycled typographical spun yarn are arranged in the yarn length direction with relatively less twist than the wrapped fibers in the surface layer, the wrapped fibers in the surface layer are twisted in one direction to form a true twist, and the wrapped fibers in the surface layer bundle the internal fibers together, and the number of fluffs per 10 m of the single yarn of the flame-retardant recycled typographical spun yarn is 0.1 to 10 fluffs for lengths of 3 mm or more and 0 to 2 fluffs for lengths of 5 mm or more. 7. The flame-retardant recycled spun yarn according to any one of 1 to 6 above, wherein the flame-retardant recycled fiber constitutes 10 to 90% by weight of the entire spun yarn. 8. The flame-retardant recycled spun yarn according to 7 above, which contains 10 to 90% by weight of the entire spun yarn of flame-retardant non-recycled fibers having a fiber length of 30 to 200 mm. 9. The flame-retardant recycled spun yarn according to any one of 1 to 8 above, which contains 0.1 to 5% by weight of conductive fibers based on the total weight of the spun yarn. 10. A flame-retardant recycled fabric comprising the flame-retardant recycled bundled spun yarn described in any one of 1 to 9 above. 11. The flame-retardant recycled fabric according to 10 above, which has a pilling resistance of grade 4 or higher after 10 hours as measured according to JIS L1076.8.11 (Method A). 12. A flame-retardant recycled fabric as described in 10 or 11 above, which has an after-flame time and after-glow time of 2 seconds or less and a char length of 10 cm or less, as measured according to JIS L1091 A-4 method (1992). 13. A method for producing a flame-retardant recycled typified spun yarn, characterized in that a typified spun yarn is obtained by applying an oil agent to a flame-retardant woven fabric suitable for recycling that satisfies the following formula (1) at least at one of the stages before cutting, after cutting, before shredding, and after shredding, and then opening the fabric, and using the flame-retardant recycled fibers containing 10% or more staple fibers having a fiber length of 20 mm or more, and / or flame-retardant recycled fibers containing 10% or more staple fibers having a length of 40% or more of the staple fiber length of the woven fabric. Twist factor × fabric packing density ≦ 4.5 (1) 14. A method for producing a flame-retardant recycled tying spun yarn as described in 13, wherein the internal fibers of the spun yarn are arranged in the length direction of the yarn with relatively less twist than the wrapped fibers on the surface, the wrapped fibers on the surface of the spun yarn are twisted in one direction to form a true twist, and the wrapped fibers on the surface are bundled with the internal fibers. [Effects of the Invention]

[0010] According to the present invention, there are provided a flame-retardant recycled spun yarn and a flame-retardant recycled fabric, which have improved openability of recycled fibers and good quality in appearance, fluff, etc., and a method for producing the same. DETAILED DESCRIPTION OF THE INVENTION

[0011] Hereinafter, embodiments of the present invention will be described in detail. First, the present invention is a flame-retardant recycled spun yarn "Voltexx spun yarn," which is a bundled spun yarn (hereinafter sometimes referred to as "spun yarn") characterized by including flame-retardant recycled fibers to which an oil agent has been applied. By using flame-retardant recycled fibers to which an oil agent has been applied, the yarn contains relatively long staple fibers, improving the quality. In this case, it is preferable that the flame-retardant recycled fibers contain 10% or more staple fibers having a fiber length of 20 mm or more. It is also preferable that the flame-retardant recycled fibers contain 10% or more staple fibers having a length of 40% or more of the staple fiber length before recycling. Hereinafter, a detailed description will be given.

[0012] First, it is preferable to pre-wash the flame-retardant textile suitable for recycling that will be used to produce flame-retardant recycled fibers. This washing process removes dirt, impurities, oil, and other contaminants adhering to the textile, thereby preventing equipment trouble and enabling efficient recycling. Washing is also preferable in terms of improving the quality of the recycled product. It also allows checking whether the flame-retardant textile suitable for recycling that serves as the raw material can be reused and whether various miscellaneous substances are present in the product.

[0013] The washing method is not particularly limited, and known means may be used. In particular, it is preferable to use a washing method in which the object to be washed is subjected to conventional rotary washing and an impact to knock off the dirt, or an Obermeyer dyeing machine, in addition to dissolving or separating dirt and oil using a detergent or solvent. It is also preferable to perform a drying treatment before applying an oil agent in the next step.

[0014] In the present invention, it is important to apply an oil to the flame-retardant woven fabric at least at one of the following stages: before cutting, after cutting, before shredding, and after cutting. By applying an oil in this manner, static electricity can be suppressed during the cutting (shredding), fiber-opening, and spinning processes, thereby advantageously facilitating these processes. The oil preferably contains an antistatic agent, such as a metal salt of alkyl phosphate ester. It also preferably contains a silicone-based component as a smoothing agent. The amount of oil applied is preferably 0.2 to 1.0 wt. % based on the weight of the flame-retardant recycled fiber. It is more preferably 0.2 to 0.8 wt. %, and particularly preferably 0.2 to 0.6 wt. %.

[0015] Here, the shredding process mechanically decomposes and separates the flame-retardant fabric suitable for recycling into threads, fragments, and cotton-like fibers, making the fiber-opening process easier and facilitating the flocculation process compared to directly opening the product. The shredding process in the present invention is not particularly limited, and known means may be used. The more staple fibers in the cotton-like material obtained in the subsequent fiber-opening process that are close to their original length, the more likely it is that the material will be recycled into a spun yarn with a high recovery of tensile strength. Therefore, in the cutting (shredding) process in the present invention, a process that maximizes the proportion of staple fibers that are as close to their original length as possible is preferred.

[0016] The cutting (shredding) process may include roughly cutting the flame-retardant fabric suitable for recycling. In this case, it is preferable to lengthen the cutting intervals depending on the form of the product so as to maximize the content of staple fibers that are as close to the original length as possible. For example, the cutting intervals may be equal to or greater than the length of the staple fibers of the spun yarn used in the flame-retardant fabric suitable for recycling. It is also preferable to tear and shred the product by biting, tearing, and pulling it out. Furthermore, the opening process may be performed in a single step by scraping and scraping.

[0017] The conditions for the opening process vary depending on the shape of the flame-retardant fabric suitable for recycling, the type of flame-retardant fiber used in the fabric, the type of opening machine, and other factors. Appropriate conditions can be determined by conducting appropriate tests depending on the flame-retardant fabric suitable for recycling raw materials. However, it is preferable to select the opening conditions so that the cotton-like material obtained by the opening process contains staple fibers 20 mm or longer in length at a ratio of 10% by weight or more (more preferably 50-90% by weight) of the spun yarn. It is also preferable to select the opening conditions so that staple fibers having a length 40% or more of the staple fiber length of the spun yarn used in the original product at a ratio of 10% by weight or more (more preferably 50-90% by weight) of the spun yarn. As mentioned above, the greater the number of staple fibers with longer lengths, in other words, lengths close to the original fiber length, the greater the recovery of the tensile strength of the recycled spun yarn (the ratio of the tensile strength of the recycled flame-retardant spun yarn to the tensile strength of the commercially available spun yarn). The fiber length distribution can be easily measured using a staple diagram in accordance with JIS L 1015-2010 8.4.1 Method A. The fiber opening can be performed using a known fiber splitter or fiber opener.

[0018] The flame-retardant recycled fiber thus obtained is substantially free of crimps, and preferably has a crimp count of 1.0 crimps / inch (2.54 cm) or less as measured according to JIS L1015:2010.

[0019] The flame-retardant woven fabric suitable for recycling and used in the present invention contains a flame-retardant spun yarn, and satisfies the following formula (1) with the twist coefficient calculated from the twist number and count of the spun yarn, and the woven fabric packing density calculated from the weave of the woven fabric and the count of the spun yarn. Twist factor × fabric packing density≦4.5 (1)

[0020] Here, the twist coefficient can be calculated as K = T / √n, where K is the twist coefficient, T is the number of twists per inch (2.54 cm), and n is the English cotton count. From the viewpoint of the physical properties and flexibility of the fabric, the twist coefficient K is preferably in the range of 2.5 to 6.0. In particular, it is preferable that the twist coefficient K is 2.5 to 4.5 for single yarns and 3.0 to 6.0 for two-ply yarns. The spun yarn may be either single yarn or two-ply yarn, and the twist coefficient is calculated from the number of twists of the final yarn. In the case of a single-yarn fabric (a fabric made from a single-yarn spun yarn), the twist coefficient is calculated from the number of first twists of the single yarn, and in the case of a two-ply fabric (a fabric made from a two-ply spun yarn), the twist coefficient is calculated from the number of top twists of the two-ply yarn.

[0021] The fabric packing density is calculated as follows: Fabric packing density=(ta1+ta2) / (tm1+tm2) Here, ta1 is the amount of yarn actually occupied in one complete design in the warp direction, and is the warp density per cm (counts / cm). Similarly, ta2 is the amount of yarn actually occupied in one complete design in the weft direction, and is the weft density per cm (counts / cm). tm1 is the amount of the theoretically largest yarn that can be occupied in one complete design in the warp direction, and tm2 is the amount of the theoretically largest yarn that can be occupied in one complete design in the weft direction. tm can be expressed by the following formula. tm=e / ((ei)×3.14×d / 4+2id) Here, e is the number of warp threads in one complete weave in the case of tm1 (weft threads in the case of tm2), and i is the number of warp crossings in one complete weave in the case of tm1 (weft crossings in the case of tm2). In the present invention, it is preferable that the values ​​of e and i are the same for the warp and weft, but they may be different.

[0022] Also, d is the diameter of the thread and can be expressed by the following formula. d(cm)=0.00357×√((tex / (φ×ρf)) Here, tex is the numerical value obtained by converting the spun yarn count into tex, φ is the filling factor of the yarn, and ρf is the specific gravity of the fiber. For simplicity, the filling factor of the yarn φ is calculated as 1 in this application.

[0023] If the twist number of the spun yarn is too high, it may become difficult to open the yarn during the disintegration and recovery processes. Similarly, if the fabric packing density is too high, it may become difficult to open the yarn during the disintegration and recovery processes. When the product of the twist coefficient and the fabric packing density is 4.5 or less (more preferably 0.1 to 4.0), it is preferable because opening the yarn during the disintegration and recovery processes becomes easier.

[0024] The spun yarn contained in the flame-retardant fabric suitable for recycling contains a flame-retardant fiber. Examples of such a flame-retardant fiber include meta-aramid fiber (meta-type wholly aromatic polyamide fiber), para-aramid 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. One or more of these flame-retardant fibers can be used. In this case, the flame-retardant fiber preferably has a limiting oxygen index of 25 or more as measured by JIS L1091-1999 E method.

[0025] Among these, meta-aramid fibers, i.e., metaphenylene isophthalamide fibers (commercially available products include "Teijin Conex" (trademark) and "Teijin Conex Neo" (trademark) manufactured by Teijin Limited, and "Nomex" (trademark) manufactured by DuPont) are useful because of their excellent limiting oxygen index and excellent mechanical properties. Furthermore, it is also preferable to mix para-aramid 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).

[0026] These flame-retardant fibers may contain additives such as antioxidants, ultraviolet absorbers, heat stabilizers, flame retardants, titanium oxide, colorants, and inert fine particles, as long as the object of the present invention is not impaired.

[0027] The spun yarn contained in the flame-retardant fabric suitable for recycling is preferably composed solely of the flame-retardant fibers described above, but may also contain non-flame-retardant fibers. In this case, the content of the flame-retardant fibers is preferably 40% by weight or more of the total yarn. Examples of non-flame-retardant fibers include polyester fibers, nylon fibers, rayon fibers, polynosic fibers, lyocell fibers, acrylic fibers, vinylon fibers, cotton, hemp, and wool. One or more of these non-flame-retardant fibers can be used.

[0028] These non-flame retardant fibers may contain additives such as antioxidants, ultraviolet absorbers, heat stabilizers, flame retardants, titanium oxide, colorants, inert fine particles, and conductive particles, as long as the purpose of the present invention is not impaired.

[0029] Furthermore, the twist factor K of the spun yarn is preferably in the range of 2.5 to 6.0 in terms of the physical properties and flexibility of the woven fabric, where T=K√n, where T is the number of twists per inch (2.54 cm), n is the British cotton count, and K is the twist factor. The spun yarn may be either a single yarn or a two-ply yarn.

[0030] The flame-retardant fabric suitable for recycling has the above-mentioned structure, which allows efficient and sufficient opening during recycling. The flame-retardant fabric suitable for recycling is preferably a virgin flame-retardant spun yarn fabric, a used flame-retardant spun yarn fabric, etc. In addition, the flame-retardant fabric may also include process waste generated during fabric production, sewing waste generated during sewing, etc.

[0031] In the present invention, a flame-retardant fabric suitable for recycling (including fabrics obtained from textile products using flame-retardant fabric suitable for recycling) is washed as necessary, and then an oil is applied before and / or after cutting to form a cut product, and the cut product is opened to obtain flame-retardant recycled fibers, which are used to produce a flame-retardant recycled spun yarn (recycled spun yarn).

[0032] Here, the textile product is not particularly limited as long as it contains a flame-retardant fabric suitable for recycling. Specific examples include flame-retardant work clothes, firefighting uniforms, work gloves, and low-cost industrial materials (woven fabrics) containing flame-retardant yarn. Such flame-retardant fabrics suitable for recycling and textile products using them preferably contain flame-retardant spun yarn alone. However, they may also contain yarns other than the flame-retardant spun yarn, preferably spun yarns. In this case, it is preferable that the content of the flame-retardant spun yarn is 50% by weight or more of the total textile product. The used flame-retardant spun yarn product used in the present invention may include not only used products of the above-mentioned flame-retardant spun yarn products, but also fiber waste and leftovers generated in the process of manufacturing the flame-retardant spun yarn products. Each step will be described in detail below.

[0033] The cotton-like material obtained by the above-mentioned opening treatment is spun to produce a shied spun yarn, and in this case, the shied spun yarn preferably contains the flame-retardant recycled fiber in an amount of 10 to 90% by weight of the entire shied spun yarn. Here, before spinning, virgin (“non-recycled”) staple fibers may be mixed with the cotton-like material obtained by opening the cut and crushed materials in a proportion of up to 90% by weight (more preferably 10 to 90% by weight, and even more preferably 10 to 70% by weight) of the total. The addition of virgin staple fibers has the advantage of more effectively restoring the tensile strength of the recycled spun yarn. Crimped staple fibers are preferred as the virgin staple fibers. This is because the presence of crimps makes it easier to open strands or tow-shaped fibers. Furthermore, staple fibers with a length of approximately 30 mm or more (more preferably 30 to 200 mm) are preferred. The longer the virgin staple fibers, the more cotton-like material obtained in this invention will be, and the longer they will be entangled, enhancing the binding effect and resulting in a flame-retardant recycled shied spun yarn with better restored tensile strength.

[0034] The virgin short fibers used in the present invention include (a) commercially available flame-retardant staple fibers, or (b) short fibers obtained from fiber waste and remnants generated during the process of manufacturing flame-retardant long fibers or products made from said long fibers. These preferably have a length of 30 to 200 mm and have a crimp that makes them easy to open. The short fibers (b) can be obtained by cutting fiber waste and remnants generated during the process of manufacturing flame-retardant long fibers or products made from said long fibers.

[0035] The method for mixing virgin staple fibers into the cotton-like material is not particularly limited, and any known mixing method, such as blending cotton with polyethylene terephthalate fibers, may be used. The virgin staple fibers may be mixed during spinning, preferably during the blending and spun process. Conductive fibers may be mixed into the spun yarn at a ratio of 0.1 to 5% by weight before or during spinning.

[0036] The structure of the flame-retardant recycled shied spun yarn is such that the inner fibers are aligned in the yarn length direction with relatively less twist than the surface layer wrapping fibers, the surface layer wrapping fibers are twisted in one direction, and the surface layer wrapping fibers bundle the inner fibers. For example, the inner fibers are aligned in the yarn length direction with no twist or nearly no twist, and the surface layer wrapping fibers are wrapped in one direction and bundle the inner fibers. The inner and surface layer fibers are intertwined from the surface to the inside due to migration. The appearance of the spun yarn is a twisted, wrapped, true twist. This spun yarn can be produced using the spinning machine described in Japanese Patent No. 2806380. This spinning machine is manufactured by Murata Machinery Co., Ltd. and sold under the product name "MURATA VORTEX SPINNER." This spinning machine is different from the spinning machine described in Patent Document 1. The spun yarn described in Patent Document 1 has intermittent binding points, but the spun yarn of the present invention has no intermittent binding points and is a true-twist spun yarn, and the yarn structure is also different. The flame-retardant recycled typified spun yarn of the present invention has little fuzz, and the woven fabric has good pilling resistance. This is due to the yarn structure of the typified spun yarn described above. As a result, fuzz is low, fibers do not fall off even when worn, and the yarn remains strong. In the above, "unidirectional" refers to S-twist wrapped fibers or Z-twist wrapped fibers, and does not mean that the twist angle is the same. Whether the wrapped fibers are S-twisted or Z-twisted is determined by the direction of the compressed air swirl flow in the spinner of the spinning machine.

[0037] The number of fluffs per 10 m of the flame-retardant recycled shim spun single yarn is preferably 0.1 to 10 for lengths of 3 mm or more, and 0 to 2 for lengths of 5 mm or more. More preferably, the number of fluffs per 10 m of the yarn is 50 to 300 for lengths of 1 mm or more, 0.5 to 10 for lengths of 3 mm or more, and 0 to 2 for lengths of 5 mm or more. The reason for the low fluff is as described above.

[0038] The flame-retardant recycled spun yarn (single yarn) is preferably in the range of British cotton count 10 to 50 (fineness: 590 to 118 dtex), which allows for the production of protective clothing with good workability.

[0039] In the woven fabric of the present invention, it is preferable to twist two of the flame-retardant recycled shied spun yarns (single yarns) together to form a two-ply yarn, which is then woven into a fabric. The reason for using two-ply yarn is that it has a strength more than twice that of a single yarn, imparts a cohesive force that prevents yarn breakage during weaving, and offsets the thickness unevenness of the single yarn, resulting in a high-quality appearance of the woven fabric. One example of a two-ply yarn is produced using a twisting machine such as a double twister. As the name suggests, a double twister provides two twists with one rotation of the spindle, making it highly productive. Preferably, a ring twister, and most preferably an up twister, is used for twisting.

[0040] The British cotton count of the two-ply yarn is preferably in the range of 10 to 50 two-ply yarn (fineness: 1180 to 236 dtex). The resulting two-ply yarn is twisted and used as the warp and weft to make a woven fabric. The weave may be plain weave, twill weave (also called twill weave), satin weave, or other variations. When making a knitted fabric, any of flat knitting, circular knitting, and warp knitting may be used. Any knitting structure is acceptable.

[0041] In the flame-retardant recycled fabric of the present invention, the weight per unit area (basis weight) is 100 to 340 g / m 2 Within this range, the work clothes can be made even lighter and more comfortable to wear. More preferably, it is 120 to 300 g / m 2 In particular, the range of 140 to 280 g / m 2 The range is.

[0042] The flame-retardant recycled fabric of the present invention is a fabric using the flame-retardant recycled shim spun yarn as the warp and weft. The flame-retardant recycled fabric preferably has a pilling resistance of grade 4 or higher after 10 hours, as measured according to JIS L1076.8.11 (Method A).

[0043] Furthermore, the flame-retardant recycled fabric preferably has an afterflame time and afterglow time of 2 seconds or less and a char length of 10 cm or less, as measured according to JIS L1091 A-4 method (1992).This allows for the provision of flame-retardant protective clothing that can be used for a long period of time without causing poor appearance.

[0044] The protective clothing of the present invention is suitable as work clothing for emergency personnel, rescuers, marine rescue personnel, the military, workers at oil-related facilities, and chemical plant workers, in addition to firefighting clothing. [Example]

[0045] The present invention will be described in more detail below with reference to examples, but the present invention is not limited to these examples. The measurements in the examples were carried out using the following methods. 1 inch is equal to 2.54 cm.

[0046] (1) Twist coefficient K The twist factor was calculated as K = T / √n, where K is the twist factor, T is the number of twists per inch (2.54 cm), and n is the English cotton count.

[0047] (2) Fabric packing density The fabric packing density was calculated using the following formula: Fabric packing density=(ta1+ta2) / (tm1+tm2) Here, T is the filling rate of the fabric, ta1 is the amount of yarn actually occupied in one complete weave in the warp direction, and is the warp density per cm (counts / cm). Similarly, ta2 is the amount of yarn actually occupied in one complete weave in the weft direction, and is the weft density per cm (counts / cm). tm1 is the amount of the theoretically largest yarn that can be occupied in one complete weave in the warp direction, and tm2 is the amount of the theoretically largest yarn that can be occupied in one complete weave in the weft direction. tm was calculated using the following formula. tm=e / ((ei)×3.14×d / 4+2id) Here, e is the number of warp (or weft) yarns in one complete weave, i is the number of warp (or weft) crossings in one complete weave, and d is the diameter of the yarn, calculated using the following formula: d(cm)=0.00357×√((tex / (φ×ρf)) Here, tex is the value obtained by converting the spun yarn count into tex, φ is the yarn packing ratio, and ρf is the specific gravity of the fiber. For simplicity, the yarn packing ratio φ was calculated as 1.

[0048] (3) Fiber length distribution The fiber length distribution was measured by measuring staple diagrams in accordance with JIS L 1015:2010 8.4.1 Method A. The proportion of fibers with a fiber length of 20 mm or more in the examples was calculated by digitizing and graphing the obtained staple diagrams and using the following formula, as described in the examples of Japanese Patent No. 3782061. Ratio of fiber lengths of 20 mm or more (%) = Area (1) / Area (2) x 100 Here, area (1) is the area of ​​the staple diagram with a fiber length of 20 mm or more, Area (2) is the area of ​​the entire staple diagram.

[0049] (4) Flame retardancy of fibers The limiting oxygen index (LOI) specified in JIS 1091:1999 E-2 was measured.

[0050] (5) Opening degree of recycled fibers The degree of opening of the recycled fibers was calculated using the following formula. Opening rate (%) = (Wt-W) / Wt x 100 Here, W is the weight (g) of unopened fibers remaining in the recycled fiber in the form of threads, etc., and Wt is the total weight (g) of the recycled fiber. This allows us to express the percentage (%) of opened fibers in the recycled fiber.

[0051] (6) Number of crimps The number of crimps was measured in accordance with JIS L 1015:2010.

[0052] (7) Amount of oil applied After weighing 2 g of raw cotton (W1) and an aluminum dish (W2), they were immersed in 15 ml of ethanol using a rapid extractor and pressed down to extract the oil onto the aluminum dish. After evaporating the ethanol from the aluminum dish to dryness, the aluminum dish (W3) was weighed and the amount of oil attached (opu, unit: %) was calculated using the following formula. opu(%)=((W3-W2) / W1)×100

[0053] (8) Number of defects (neps) The number of defects was measured using a yarn unevenness tester equipped with a defect number display device based on JIS L1095 Method B: 2010, and the number of yarn defects (neps) at +200% of the average thickness was measured. The number of yarn defects (neps) per 1000m was rounded to the nearest integer.

[0054] (9) Fabric weight and density The fabric weight, warp and weft densities were measured according to JIS L1096.

[0055] (10) Pilling test Pilling resistance was measured after 10, 20, and 30 hours using JIS L1076.8.11 (Method A). The rating ranges from Grade 1 to Grade 5, with the higher the rating, the better the anti-pilling properties. Grades between Grade 4 and 5 are displayed as "Grade 4-5."

[0056] (11) Flammability Afterflame time, afterburn time, and char length were measured according to JIS L1091-1992 A-4 method.

[0057] (12) Fluff index According to JIS L1095 9.22 B method, fluff of 1 mm, 3 mm and 5 mm was measured over a 10 m length using a fluff measuring tester (F-Index Tester manufactured by Shikishima Boseki Co., Ltd.).

[0058] [Example 1] The recycled textile product used was a flame-retardant workwear fabric composed of 95% by weight of meta-aramid fiber and 5% by weight of para-aramid fiber. The fabric was made of a 40-count, two-ply flame-retardant spun yarn composed of 95% by weight of polymetaphenylene isophthalamide fiber (Teijin Conex, trademark manufactured by Teijin Limited) and 5% by weight of coparaphenylene-3,4'-oxydiphenylene terephthalamide fiber (Technora, trademark manufactured by Teijin Limited). The final twist was 19.8 turns / 2.54 cm (S twist). The fabric was a 2 / 2 twill weave with a warp density of 86 threads / 2.54 cm and a weft density of 75 threads / 2.54 cm. The parameters required for fabric packing density were e = 4, i = 2, and d = 0.0165. The twist factor of this fabric was 4.43, the packing density of the fabric was 0.73, and the twist factor x packing density of the fabric was 3.23.

[0059] The fabric was cut into approximately 5cm squares, washed and dried, and then treated with an oil to improve antistatic properties and smoothness. The oil contained potassium lauryl phosphate as an antistatic agent and a silicone-based component as a smoothing agent. The amount of oil attached to the flame-retardant recycled fiber was 0.35% by weight.

[0060] The cut flame-retardant fabric was then subjected to a crushing process and then to a fiber-opening process using a rewinder. The resulting recycled fibers (including insufficiently opened filaments) had good fiber-opening properties, and 30% by weight of this fiber was mixed with 70% by weight of virgin polymetaphenylene isophthalamide fiber (Teijin Conex Neo (trade name), CN, manufactured by Teijin Limited) with a fineness of 1.7 dtex and a fiber length of 51 mm. The mixture was passed through a carding process and a drawing process, and then a flame-retardant recycled shied spun yarn (20 count / single yarn) according to the present invention was produced using a Murata Machinery Co., Ltd. No. 870 MURATA VORTEX SPINNER at a speed of 400 m / min. Next, two shied spun single yarns were twisted using a double twister to form a two-ply yarn. The twist number was 14.4 times / 2.54 cm, and the twist coefficient K was 4.55.

[0061] The two-ply yarn was used as the warp and weft to produce a plain weave fabric using a rapier loom. Next, the fabric was dyed in a dye bath containing a predetermined cationic dye (Kayacryl (trade name) manufactured by Nippon Kayaku Co., Ltd.) at a temperature raised from room temperature to 130°C for 60 minutes. The dyeing was carried out by placing each fabric in the dye bath, setting it in a jet dyeing machine (High Temperature Circular manufactured by Hisaka Works, Ltd.), and stirring it under the temperature conditions mentioned above.

[0062] Next, 1 g / L of hydrosulfite, 1 g / L of soda ash, and a surfactant (1 g / L of Amylazine D manufactured by Meisei Chemical Co., Ltd.) were dissolved in water to prepare a post-treatment bath for reduction washing. The dyed fabric was placed in this post-treatment bath and placed in the jet dyeing machine. The temperature was increased from room temperature to 80°C at a rate of 2°C / min while stirring, and then held at 80°C for 20 minutes to perform reduction washing. After cooling, the dyed fabric was removed, washed with water, air-dried, and heat-treated for finishing. Heat treatment was performed at 190°C for 2 minutes to obtain a dyed, flame-retardant recycled fabric. The openability of the resulting recycled fiber, the proportion of fibers with a fiber length of 20 mm or more, and the physical properties of the shied spun yarn and fabric are shown in Table 1.

[0063] [Example 2] The recycled textile product used was a flame-retardant workwear fabric composed of 95% by weight of meta-aramid fiber and 5% by weight of para-aramid fiber. The fabric was made of a 36-count, two-ply flame-retardant spun yarn composed of 95% by weight of polymetaphenylene isophthalamide fiber (Teijin Conex, trademark, manufactured by Teijin Limited) and 5% by weight of coparaphenylene-3,4'-oxydiphenylene terephthalamide fiber (Technora, trademark, manufactured by Teijin Limited). The final twist was 19.8 turns / 2.54 cm (S twist). The fabric was plain weave with a warp density of 60 threads / 2.54 cm and a weft density of 49 threads / 2.54 cm. The parameters required for fabric packing density were e = 2, i = 2, and d = 0.0174. The twist coefficient of the two-ply yarn of this fabric was 4.66, the packing density of the fabric was 0.75, and the twist coefficient x packing density of the fabric was 3.48. The fabric was treated in the same manner as in Example 1 to produce a flame-retardant recycled shim spun yarn of 20 count / single yarn according to the present invention. The obtained flame-retardant recycled spun yarn was woven and dyed in the same manner as in Example 1 to obtain a dyed flame-retardant recycled fabric. The results are shown in Table 1.

[0064] [Example 3] The recycled textile product used was a flame-retardant workwear fabric composed of 95% by weight of meta-aramid fiber and 5% by weight of para-aramid fiber. The fabric was made of a 40-count flame-retardant spun yarn consisting of 95% by weight of polymetaphenylene isophthalamide fiber (Teijin Conex, trademark, manufactured by Teijin Limited) and 5% by weight of coparaphenylene-3,4'-oxydiphenylene terephthalamide fiber (Technora, trademark, manufactured by Teijin Limited). The number of twists was 24.0 turns / 2.54 cm (Z twist). The fabric was plain weave with a warp density of 53 threads / 2.54 cm and a weft density of 53 threads / 2.54 cm. The parameters required for the fabric packing density were e = 2, i = 2, and d = 0.0117. The twist coefficient of the single yarn of this woven fabric was 3.79, the packing density of the woven fabric was 0.49, and the twist coefficient x packing density of the woven fabric was 1.85. The woven fabric was treated in the same manner as in Example 1 to produce a flame-retardant recycled shim spun yarn of 20 count / single yarn according to the present invention. The openability of the obtained recycled fiber, the proportion of fibers with a fiber length of 20 mm or more, and the physical properties of the spun yarn are shown in Table 1. The obtained flame-retardant recycled spun yarn was woven and dyed in the same manner as in Example 1 to obtain a dyed flame-retardant recycled woven fabric. The results are shown in Table 1.

[0065] [Comparative Example 1] The same recycled textile product as in Example 1 was used for recycling, and the process was carried out in the same manner as in Example 1 to obtain a flame-retardant recycled fiber. 30% by weight of this fiber was mixed with 70% by weight of virgin polymetaphenylene isophthalamide fiber (Teijin Conex Neo (trade name) manufactured by Teijin Limited) with a fineness of 1.7 dtex and a fiber length of 51 mm. The mixture was passed through carding, drawing, and roving processes, and then twisted to 15.2 turns per inch (2.54 cm). A ring spinning frame was used to produce a ring-spun single yarn (not a shied spun yarn) with a British cotton count of 20. The resulting flame-retardant recycled spun yarn was woven and dyed in the same manner as in Example 1 to obtain a dyed flame-retardant recycled textile. The results are shown in Table 1.

[0066] Comparative Example 2 The recycled textile product used for recycling was the same as in Comparative Example 1, and the treatment of the textile was carried out in the same manner as in Comparative Example 1, except that no oil agent was applied, to produce the flame-retardant spun yarn of the present invention. The obtained flame-retardant recycled spun yarn was used to weave and dye a dyed flame-retardant recycled woven fabric in the same manner as in Example 1. The results are shown in Table 1.

[0067] Comparative Example 3 The recycled textile product used was a flame-retardant workwear fabric composed of 95% by weight of meta-aramid fiber and 5% by weight of para-aramid fiber. The fabric was made of a 35-count / two-ply flame-retardant spun yarn composed of 95% by weight of polymetaphenylene isophthalamide fiber (Teijin Conex, trademark, manufactured by Teijin Limited) and 5% by weight of coparaphenylene-3,4'-oxydiphenylene terephthalamide fiber (Technora, trademark, manufactured by Teijin Limited). The final twist was 23.6 turns / 2.54 cm (S twist). The fabric was plain weave with a warp density of 65 threads / 2.54 cm and a weft density of 55 threads / 2.54 cm. The parameters required for the fabric packing density were e = 2, i = 2, and d = 0.0177. The twist coefficient of the two-fold yarn of this fabric was 5.63, the packing density of the fabric was 0.84, and the twist coefficient x packing density of the fabric was 4.70. The fabric was treated in the same manner as in Example 1, but the fibers were hardly opened and could not be used as recycled fibers.

[0068] [Reference example] In Example 1, a case where only virgin fibers were used is shown in Table 1 as a reference example.

[0069] [Table 1-1]

[0070] [Table 1-2] [Industrial Applicability]

[0071] According to the present invention, a flame-retardant recycled spun yarn using flame-retardant recycled fibers, a flame-retardant recycled fabric using the same, and a method for producing the same are provided, and these have extremely great industrial value.

Claims

1. A flame-retardant recycled spun bundle yarn, characterized in that the spun bundle yarn contains flame-retardant recycled fibers to which an oil agent has been applied.

2. The flame-retardant recycled shied spun yarn according to claim 1 , wherein the oil agent contains a silicone-based component.

3. The flame-retardant recycled shim spun yarn according to claim 1, wherein the amount of the oil applied is 0.2 to 1.0% by weight based on the weight of the flame-retardant recycled fiber.

4. The flame-retardant recycled shied spun yarn according to claim 1, wherein the number of crimps measured in accordance with JIS L1015:2010 is 1.0 crimps / 2.54 cm or less.

5. 2. The flame-retardant recycled shim spun yarn according to claim 1, wherein the flame-retardant recycled fiber is one or more fibers selected from the group consisting of meta-aramid fiber, para-aramid fiber, polyparaphenylene benzoxazole fiber, polybenzimidazole fiber, polyimide fiber, polyetherimide fiber, polyamideimide fiber, carbon fiber, polyphenylene sulfide fiber, polyvinyl chloride fiber, flame-retardant rayon, modacrylic fiber, flame-retardant acrylic fiber, flame-retardant polyester fiber, flame-retardant vinylon fiber, melamine fiber, fluorine fiber, flame-retardant wool, and flame-retardant cotton.

6. The flame-retardant recycled spun yarn according to claim 1, The internal fibers of the flame-retardant recycled tying spun yarn are arranged in the yarn length direction with relatively less twist than the wrapped fibers in the surface layer, the wrapped fibers in the surface layer are twisted in one direction to form a true twist, and the wrapped fibers in the surface layer bundle the internal fibers, and the number of fluffs per 10 m of the single yarn of the flame-retardant recycled tying spun yarn is 0.1 to 10 fluffs for lengths of 3 mm or more and 0 to 2 fluffs for lengths of 5 mm or more.

7. The flame-retardant recycled spun yarn according to claim 1, wherein the flame-retardant recycled fiber accounts for 10 to 90% by weight of the entire spun yarn.

8. The flame-retardant recycled spun yarn according to claim 7, wherein the flame-retardant non-recycled fibers having a fiber length of 30 to 200 mm account for 10 to 90% by weight of the entire spun yarn.

9. The flame-retardant recycled spun yarn according to claim 1, wherein the conductive fiber is contained in an amount of 0.1 to 5% by weight of the entire spun yarn.

10. A flame-retardant recycled fabric comprising the flame-retardant recycled spun yarn according to any one of claims 1 to 9.

11. The flame-retardant recycled fabric according to claim 10, which has a pilling resistance of grade 4 or higher after 10 hours as measured according to JIS L1076.8.11 (Method A).

12. The flame-retardant recycled fabric according to claim 10, wherein the afterflame time and afterglow time are 2 seconds or less and the char length is 10 cm or less, as measured according to JIS L1091 A-4 method (1992).

13. A method for producing a flame-retardant recycled typified spun yarn, characterized in that a typified spun yarn is obtained by applying an oil agent to a flame-retardant woven fabric suitable for recycling that satisfies the following formula (1) at least at one stage among before cutting, after cutting, before shredding, and after shredding, and then opening the fabric, and the resulting flame-retardant recycled fiber contains 10% or more staple fibers having a fiber length of 20 mm or more, and / or a flame-retardant recycled fiber contains 10% or more staple fibers having a length of 40% or more of the staple fiber length of the woven fabric. Twist coefficient × fabric packing density ≦ 4.5 (1)

14. A method for producing a flame-retardant recycled tying spun yarn as described in claim 13, wherein the internal fibers of the spun yarn are arranged in the yarn length direction with relatively less twist than the wrapped fibers in the surface layer, the wrapped fibers in the surface layer of the spun yarn are twisted in one direction to form a true twist, and the wrapped fibers in the surface layer are bundled with the internal fibers.

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