Mattress fabric and its manufacturing method

Abstract

The present invention relates to a mattress fabric comprising a knitted fabric formed by knitting a blended yarn containing flame-retardant rayon, modacrylic fiber, polyimide fiber, and low-melting-point polyester fiber. The mattress fabric can be obtained by producing a blended yarn containing flame-retardant rayon, modacrylic fiber, polyimide fiber, and low-melting-point polyester fiber, and knitting the blended yarn to form a knitted fabric. According to the present invention, it is possible to provide a safe mattress fabric that is excellent in flame retardancy, excellent in workability for covering a mattress, does not reduce the strength of the blended yarn, suppresses the occurrence of pilling in the fabric, and does not affect contact with the human body.

Description

[Technical field]

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

[0002] A mattress is generally placed on a bed frame that makes up a bed (sleeping platform) used in each household to allow people to sleep and rest comfortably, and a cover member is provided to cover the outer peripheral surface of the tension element that provides the tension force of the mattress.

[0003] Generally, the basic performance of a mattress is heat retention, breathability, and resilience, and it is also important to have the durability to maintain its bulk even after long-term use. In other words, it is necessary for the mattress to have heat retention to maintain the user's body temperature, smooth ventilation of the air inside and outside the mattress, and good contraction and resilience under the weight of the user.

[0004] Mattresses are usually rectangular in shape and generally consist of a core, an interior material, and a cover. The core has the greatest influence on the feel of the mattress, and is made of materials such as springs, latex, and memory foam (registered trademark). The interior material, which is located between the core and the cover, provides the mattress with various functions. The cover is the part that comes into direct contact with the body.

[0005] The interior materials and covers are primarily designed to have antibacterial, germicidal and deodorizing properties that affect the human body, so there are no inconveniences or problems when using them. However, if an unexpected fire occurs during use and the flames ignite the mattress, not only will the interior materials and covers, which are made of simple fiber materials, be easily incinerated, but toxic gases that are harmful to the human body will be generated during incineration, which could lead to a larger fire and loss of life.

[0006] The interior material and cover are usually integrated using a known quilting method in which the nonwoven fabric, padding, and fabric are layered from the inside to the outside, and the materials used for these have been pointed out as a major factor in the spread of mattress fires.

[0007] Therefore, various fiber materials used in mattresses are required to be flame retardant or flame resistant.

[0008] As flame-retardant or fire-resistant fibers, fiber products made from materials with excellent heat resistance, such as glass fiber or aramid, are mainly used. However, although the flame-retardant or fire-resistant functions can be ensured in such cases, there is a problem that the affinity with the human body, texture, elasticity, softness, stretchability, etc. required for mattresses are insufficient for use as interior materials for bedding. [Prior art documents] [Patent documents]

[0009] [Patent Document 1] Republic of Korea Patent Publication No. 2006-0066073 (Single-layer fireproof fabric for mattress or mattress set, and fireproofing method thereof) Summary of the Invention [Problem to be solved by the invention]

[0010] In order to solve the above-mentioned problems, the present invention aims to provide a mattress fabric that has flame retardancy and functions suitable for use as an interior material for bedding, and a manufacturing method thereof. [Means for solving the problem]

[0011] In one or more embodiments, the present invention relates to a mattress fabric comprising a knitted product obtained by knitting a blended yarn containing 20 to 70% by weight of flame-retardant rayon fiber, 10 to 30% by weight of modacrylic fiber, 10 to 30% by weight of polyimide fiber, and 5 to 20% by weight of low-melting point polyester fiber, wherein the polyimide fiber has a crimp number of 3 to 12 times per inch and a pilling resistance of grade 4 to 5 or higher as measured under conditions of a rotation speed of 14,400 in accordance with KS K 0503:2006.

[0012] In one or more embodiments, the present invention relates to a method for producing a mattress fabric, comprising the steps of: spinning a mixture of 20 to 70% by weight of flame-retardant rayon fiber, 10 to 30% by weight of modacrylic fiber, 10 to 30% by weight of polyimide fiber, and 5 to 20% by weight of low-melting point polyester fiber to produce a blended yarn; and knitting the blended yarn to produce a knitted product, wherein the polyimide fiber has a crimp number of 3 to 12 times per inch. Effect of the Invention

[0013] According to the present invention, by combining flame-retardant fiber materials, excellent flame retardancy is maintained, while the strength of the blended yarn is not reduced, and the knitting workability is not reduced when the blended yarn is applied to a knitted fabric, improving its elasticity. This makes it possible to provide a safe mattress fabric that has excellent workability for covering a mattress, suppresses the occurrence of pilling in the fabric, and does not affect contact with the human body. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0014] The inventors of the present invention have conducted extensive research to solve the above problems. As a result, they have found that by combining polyimide fiber having a specific crimp number, flame-retardant rayon (FR-Rayon) fiber, modacrylic fiber, and low melting polyester (LM PET) in specific blending ratios to prepare a blended yarn, and incorporating a knitted fabric made from the blended yarn into a mattress fabric, a mattress fabric that is excellent in flame resistance, suppresses the occurrence of pilling in the fabric, and is safe even when in contact with the human body can be obtained.

[0015] Specifically, by using a blended yarn that combines flame-retardant rayon fiber and modacrylic fiber, which are flame-retardant fibers, with polyimide fiber having a specified crimp number and low-melting point polyester fiber, a carbonized film formed by the polyimide fiber and low-melting point polyester fiber during combustion inhibits the progress of combustion, thereby significantly improving the flame resistance of the knitted material. In addition, polyimide fibers usually have a smooth fiber surface and high elongation, so that they are not easily blended with other fibers. However, in the present invention, by using polyimide fibers having a predetermined crimp number, it is possible to suppress the polyimide fibers from falling off from the blended yarn and the occurrence of pilling, and it is also possible to more easily exhibit the flame retardancy improving effect of the polyimide fibers. Furthermore, the low melting point polyester fiber enhances the cohesion between the fibers in the blended yarn, and effectively suppresses the pilling phenomenon that tends to occur with modacrylic fiber or polyimide fiber.

[0016] In one or more embodiments of the present invention, the mattress fabric comprises a knitted product obtained by knitting a blended yarn containing 20 to 70% by weight of flame-retardant rayon fiber, 10 to 30% by weight of modacrylic fiber, 10 to 30% by weight of polyimide fiber, and 5 to 20% by weight of low-melting point polyester fiber.

[0017] In one or more embodiments of the invention, a mattress fabric is made by producing a blended yarn comprising flame retardant rayon fibers, modacrylic fibers, polyimide fibers, and low melting point polyester fibers, and knitting the blended yarn into a knitted fabric.

[0018] In one or more embodiments of the present invention, the blended yarn comprises 20-70% by weight of flame retardant rayon fiber, 10-30% by weight of modacrylic fiber, 10-30% by weight of polyimide fiber, and 5-20% by weight of low melting polyester (LM PET) fiber.

[0019] Rayon is used in a variety of applications, such as the lining of outerwear and underwear, and is a fiber material that has excellent antistatic properties that prevent static electricity and is soft to the touch, preventing users from experiencing inconvenience caused by static electricity.

[0020] Flame-retardant rayon fibers are fibers to which flame retardancy has been imparted. For example, they can be produced by modifying rayon by adding a phosphorus-based flame retardant at the spinning stage of rayon. Flame-retardant rayon fibers are flame-retardant and durable to washing, and can also be dyed. It is preferable to use flame-retardant rayon fibers with a fineness of 2 to 5 d (denier).

[0021] In the above blended yarn, if the flame-retardant rayon fiber is less than 20% by weight, the flexibility and elasticity will decrease, and if it exceeds 70% by weight, even if the source of the fire is easily removed, the fire that has spread to the fabric will not be extinguished immediately, resulting in reduced flame retardancy.

[0022] Modacrylic fibers are acrylic synthetic fibers made from a polymer containing primarily acrylonitrile. Preferably, the polymer is a copolymer containing 30-70% by weight of acrylonitrile and 30-70% by weight of a halogen-containing vinyl monomer. The halogen-containing vinyl monomer is, for example, at least one monomer selected from vinyl chloride, vinylidene chloride, vinyl bromide, vinylidene bromide, etc. Examples of copolymerizable vinyl monomers include acrylic acid, methacrylic acid, salts or esters of such acids, acrylamide, methylacrylamide, vinyl acetate, etc.

[0023] A suitable modacrylic fiber is a copolymer of acrylonitrile in combination with vinylidene chloride, which may further include one or more antimony oxides for improved flame retardancy.

[0024] Modacrylic produces flame retardant gases during combustion that act as oxygen barriers, but also produce significant amounts of acid gases.

[0025] Modacrylic fiber itself has excellent strength, elasticity, flame retardancy, and chemical resistance. In addition, it is relatively inexpensive among flame-retardant fibers, and is widely used in work clothes, flame-retardant laboratory clothes, carpets, curtains, etc. However, it is prone to discoloration when exposed to sunlight, has poor dyeability, and has poor elasticity when dyed, so there are limitations to its use alone.

[0026] In the above blended yarn, if the modacrylic fiber is less than 10% by weight, the generation of flame retardant gas that is heavier than air and suppresses contact between combustible materials and oxygen during combustion is reduced, resulting in reduced flame retardancy and flame retardancy (flame retardation). If it exceeds 30% by weight, the heat resistance during combustion is low, the char length increases, and a large amount of harmful smoke is generated, causing pollution that is harmful to the human body, and a large amount of pilling occurs, reducing knitting properties and causing a nap phenomenon on the surface of the fabric.

[0027] Polyimide fibers decompose at temperatures of 450°C or higher, and therefore have excellent heat resistance and heat insulation properties, thermal stability, chemical resistance to acids and alkalis, and excellent strength.

[0028] The blended yarn has improved thermal stability, heat barrier properties, and dimensional stability due to the incorporation of polyimide fibers, and thus the knitted product made of the blended yarn of the present invention is carbonized more quickly, and has improved flame retardancy and flame resistance.

[0029] On the other hand, polyimide having high heat resistance functions as a flexible stiffener in the carbonized film, preventing the carbonized film from being damaged, thereby suppressing further combustion in the knitted material and reducing the char length.

[0030] In addition, the carbonized film remains strong, preventing heat and combustion from being transferred to the inside and thus preventing further combustion.

[0031] In the above blended yarn, if the polyimide fiber is less than 10% by weight, the thermal properties will be reduced, the carbonized area will increase, and the combustion will not be stopped quickly. If it exceeds 30% by weight, the spinnability will be reduced, the effect improvement will be slight, and it is not economically desirable.

[0032] Low melting polyester (LM PET) fibers have a melting point of 150 to 200° C., and are melted within the above temperature range to exhibit the fusion function.

[0033] When heat is applied during processing of the blended yarn or knitted fabric using the blended yarn, the low melting point polyester fiber acts as an adhesive by fusing, improving the mechanical strength and durability of the blended yarn and suppressing the occurrence of pilling, which is a drawback of spun yarn.

[0034] In addition, upon combustion, it is first melted and pyrolyzed to form a carbonized film on the knitted fabric, and this carbonized film suppresses the shrinkage of the knitted fabric and forms a film that fills the voids in the knitted fabric, thereby improving the flame retardancy and flame resistance of the knitted fabric.

[0035] In addition, since the shrinkage rates of the fibers that make up the blended yarn are different, the contact between the fibers decreases during various processes for manufacturing the fabric. However, the LM PET fiber binds the individual fibers together, improving the contact, mechanical strength, and durability.

[0036] If the low melting point polyester fiber in the above blended yarn is less than 5% by weight, pilling will occur in the knitted product, and the mechanical strength and durability will decrease. If it exceeds 20% by weight, the fabric will become hard due to heat fusion, shrinkage will occur due to heat, and the flame retardancy and fire resistance will rapidly decrease.

[0037] If the melting point of the low melting point polyester fiber is less than 150°C, the following wet heat treatment during the manufacturing process of the mattress fabric may cause the properties of the low melting point polyester fiber to deteriorate and fall off.

[0038] In one or more embodiments of the present invention, the blended yarn may be produced by mixing and spinning staple fibers of flame-retardant rayon fiber, modacrylic fiber, polyimide fiber, and low melting point polyester fiber, or by producing each of these into a sliver and combining them, or by winding another spun yarn around one type of sliver, or by a combination of such methods.

[0039] The staple fibers of the above-mentioned flame-retardant rayon fiber, modacrylic fiber, polyimide fiber and low melting point polyester fiber all have a fineness of 2-5d and a length of 37-127mm, which makes them easy to spin and improves the tensile strength of the blended yarn while maintaining its flexibility, thereby providing the knitted product with stretchability and elasticity as well as improved mechanical strength.

[0040] If the fineness is less than 2d, the mechanical strength will decrease, and if it exceeds 5d, the mechanical strength will decrease due to the reduction in the short fibers that make up the blended yarn, and the processability and flexibility of the blended yarn will be inferior.

[0041] If the length of the staple fiber is less than 37 mm, the mechanical strength is reduced, whereas if it exceeds 127 mm, the mechanical strength is increased but the spinnability is deteriorated.

[0042] Generally, spun yarn is made by blending a plurality of staple fibers. In this case, the properties of each component fiber are different from each other, and the mechanical properties of each component fiber are not fully expressed during processing such as blending and spinning.

[0043] Polyimide short fibers have a smooth surface and exhibit low modulus and high elongation properties, and are therefore not suitable for reinforcing other fibers.

[0044] In the present invention, even if the polyimide staple fiber is mixed in a small amount during spinning, the properties of the polyimide staple fiber are exhibited in the blended yarn, and in order to prevent the required properties of the blended yarn from being reduced, it is preferable that the number of crimps of the polyimide staple fiber is 3 to 12 times / inch. If the number of crimps is less than 3 times / inch, the flexibility decreases and the polyimide staple fiber may come out of the blended yarn, causing pilling or causing prickiness when touched, and if the number of crimps exceeds 12 times / inch, bending occurs and the mechanical strength decreases.

[0045] Polyimide fibers are subject to friction caused by machines and the like during processing, and are susceptible to fibrillation due to such friction, which makes the fibers susceptible to falling off during processing.

[0046] The blended yarn has a thickness of 5 to 30 and a twist number of 10 to 20 turns per inch, so that the mechanical strength of the blended yarn does not decrease, short fibers do not come out, and knitting properties do not deteriorate.

[0047] The blended yarn is not particularly limited, but from the viewpoint of excellent mechanical strength, it is preferable that the strength (tensile strength) is more than 1.29 cN / dtex, more preferably 1.35 cN / dtex or more, and even more preferably 1.40 cN / dtex or more.

[0048] For use as a mattress fabric, the blended yarn may be knitted into any type of knitted article, such as weft knit, circular knit, warp knit, etc.

[0049] In woven fabrics, the weft and warp threads form weaving points, making it difficult for the threads to move freely, and if the raw threads do not have good elasticity, it is difficult to achieve sufficient elongation.

[0050] In contrast, knitted fabrics, in which raw yarns form loops and these loops are connected to be knitted, have no weaving points, the raw yarns can move freely, and the joints deform in the direction of force, so they have much better elongation than woven fabrics.

[0051] The mattress fabric of the present invention has improved stretchability, making it easier to cover the core of the mattress.

[0052] The weight of the knitted fabric is 200 to 500 g / m 2 This results in the material exhibiting mechanical strength and durability while being lightweight.

[0053] The knitted fabric is heat-treated to fuse the low melting point polyester fibers to obtain a mattress fabric. The heat treatment can be carried out, for example, by a tenter. Preferably, the knitted fabric is dry-heat-treated at a temperature of 150 to 180°C to obtain a mattress fabric. This fuses the low melting point polyester fibers, improving the bonding strength of the fibers constituting the blended yarn. This improves the bundling property of the fibers constituting the blended yarn, making it easier to suppress the occurrence of pilling. Specifically, the knitted fabric can be dry-heat-treated in a tenter at a temperature of 150 to 180°C for 1 to 10 minutes.

[0054] A tenter is a machine that is widely used to fix fabrics with heat to match their intended use and specifications. The role of the tenter is to set the temperature, processing speed, and air volume for each chamber to improve elasticity, and apply heat to the fiber fabric based on the set conditions to maintain excellent flame retardancy and elasticity.

[0055] In the present invention, the blended yarn or knitted fabric can be subjected to a wet heat treatment at 130 to 145°C for 10 to 90 minutes in a high humidity atmosphere, and then the knitted fabric can be further subjected to a dry heat treatment at a temperature of 150 to 180°C for 1 to 10 minutes in a tenter.

[0056] In this case, the wet heat treatment may be carried out using high pressure steam in an autoclave or in a high pressure dyeing machine.

[0057] Even if pilling occurs in the blended yarn due to the above-mentioned wet heat treatment, the pilling is easily removed, and since the low melting point polyester fiber is fused by the above-mentioned dry heat treatment, the constituent fibers are less likely to come out of the blended yarn, and the occurrence of pilling is suppressed.

[0058] The mattress fabric of the present invention manufactured by the above-mentioned method has improved flame retardancy and fire resistance because the polyimide fiber reduces the generation of toxic gases and the carbonization length, and the low melting point polyester fiber increases the adhesive strength between the constituent fibers of the blended yarn, improving the mechanical strength and durability of the blended yarn and suppressing pilling, which is a drawback of spun yarn.

[0059] On the other hand, polyimide staple fibers having a crimp number of 3 to 12 times per inch improve processability in the fiber processing steps of blended yarn production and knitted fabric production, thereby improving the properties of the fiber product.

[0060] From the viewpoint of superior anti-pilling properties, the mattress fabric preferably has a pilling resistance of grade 4 to 5 or higher as measured under conditions of a rotation speed of 14,400 rpm according to KS K 0503:2006.

[0061] The mattress fabric has excellent flame retardancy and is rated at a charred area of ​​20cm2 or more, as measured according to the Korean flame retardancy standard KOFEIS 1001. 2 It is preferable that the carbonization length is 8 cm or less.

[0062] From the viewpoint of superior flame retardancy, the mattress fabric preferably has a flame after-time of 0 seconds and a glow after-time of 0 seconds, as measured based on the Korean flame retardancy standard KOFEIS 1001.

[0063] From the viewpoint of providing superior workability in covering a mattress, the mattress fabric preferably has a stretch recovery rate in both the warp direction and the weft direction of 90% or more. EXAMPLES

[0064] The present invention will now be described in more detail with reference to the following examples and comparative examples.

[0065] However, the following examples are merely for illustrative purposes only, and the present invention is not limited to the following examples. It will be apparent to those skilled in the art to which the present invention pertains that the present invention may be modified into other equivalent embodiments without departing from the technical spirit of the present invention.

[0066] [Example 1] The raw materials, 60% by weight of flame-retardant rayon staple fiber (2d×51mm), 10% by weight of modacrylic staple fiber (3d×51mm), 10% by weight of polyimide staple fiber (2d×51mm, crimp number 8 times / inch), and 20% by weight of LM PET staple fiber (2d×51mm) with a melting point of 150°C, were mixed in a combing process, and a spinning process of carding, drawing, roving, and fine spinning was carried out to produce a blended yarn with a count of 10 and a twist number of 12 times / inch.

[0067] The above blended yarn was knitted into a warp knit structure on a tricot knitting machine, and the yarn was woven into a 250 g / m 2 A knitted fabric of the above was produced.

[0068] The knitted fabric was treated in a tenter at 180° C. for 3 minutes to produce a mattress fabric.

[0069] The mattress fabric was cut into a sample measuring 6 cm in width and 25 cm in length. The sample was gripped at the centre of the sample width with a 2.5 cm wide jaw, set to a length of 15 cm and a tensile speed of 15 cm / min, and stretched using a Tensilon tensile tester until a stress of 4.9 N / cm was applied. The elongation rate was then measured by returning the sample to the position of zero displacement at the same speed.

[0070] The elongation recovery rate was calculated according to the following mathematical formula 1.

[0071] [Mathematical formula 1] Elongation recovery rate (%)=(L1-L0)×100 L1: 4.9N / cm extension length (cm) L0: Length from the origin when the stress becomes 0 after recovery (cm)

[0072] The measurement results showed that the warp elongation rate was 21%, the elongation recovery rate was 95%, the weft elongation rate was 83%, and the elongation recovery rate was 91%.

[0073] The mattress fabric was easily covered with the mattress core, and it was determined that this was due to the excellent elongation properties of the mattress fabric, as described above.

[0074] [Example 2] A mattress fabric was produced in the same manner as in Example 1, except that the blended yarn was subjected to a wet heat treatment at 140°C for 30 minutes in a cheese state before being knitted.

[0075] [Comparative Example 1-6] A mattress fabric was produced in the same manner as in Example 1, except that the content of the staple fibers constituting the blended yarn and the crimp number of the polyimide staple fibers were changed as shown in Table 1 below.

[0076] [Table 1]

[0077] The flame retardancy of the mattress fabrics produced in the above Examples and Comparative Examples was measured by the following method, and the results are shown in Table 2 below.

[0078] At this time, the flame retardant performance measurement experiment was carried out based on KOFEIS 1001, a general flame retardant performance standard.

[0079] [Table 2]

[0080] The properties of the blended yarns produced in the above examples and comparative examples are shown in Table 3 below.

[0081] [Table 3]

[0082] The pilling properties of the mattress fabrics manufactured in the above Examples and Comparative Examples were measured at 14,400 revolutions per minute in accordance with KS K 0503:2006.

[0083] The results are shown in Table 4 below.

[0084] [Table 4]

[0085] From the above evaluation results, it is confirmed that the mattress fabric of the present invention provides a safe material that has improved flame retardancy, is excellent in workability for covering a mattress, does not reduce the strength of the blended yarn, suppresses the occurrence of pilling in the fabric, and does not affect contact with the human body.

Claims

1. The knitted product includes a blended yarn containing 20 to 70% by weight of flame-retardant rayon fiber, 10 to 30% by weight of modacrylic fiber, 10 to 30% by weight of polyimide fiber, and 5 to 20% by weight of low-melting-point polyester fiber, The polyimide fiber has a crimp number of 8 to 12 times per inch; The blended yarn has a thickness of 5 to 30 and a twist number of 10 to 20 turns per inch; The knitted fabric has a basis weight of 200 to 500 g / m 2 , In the knitted product, the low melting point polyester fibers are fused, A mattress fabric characterized in that its pilling resistance measured under conditions of 14,400 revolutions per minute based on KS K 0503:2006 is grade 4 to 5 or higher.

2. 2. The mattress fabric according to claim 1, wherein the flame-retardant rayon fiber, the modacrylic fiber, the polyimide fiber, and the low-melting-point polyester fiber all have a fineness of 2 to 5d and a length of 37 to 127mm.

3. The charred area measured based on the Korean flame retardant standard KOFEIS 1001 is 20 cm 2 3. The mattress fabric according to claim 1 or 2, having a carbonization length of 8 cm or less.

4. 4. The mattress fabric according to claim 1, which has a flame after-time of 0 seconds and a glow after-time of 0 seconds, as measured based on the Korean flame retardancy standard KOFEIS 1001.

5. 5. The mattress fabric according to claim 1, wherein the stretch recovery rate in the warp direction and the stretch recovery rate in the weft direction are both 90% or more.

6. The mattress fabric according to any one of claims 1 to 5, wherein the blended yarn has a strength of more than 1.29 cN / dtex.

7. A method for producing a mattress fabric according to any one of claims 1 to 6, comprising the steps of: A step of spinning the yarn to prepare a blended yarn containing 20 to 70% by weight of flame retardant rayon fiber, 10 to 30% by weight of modacrylic fiber, 10 to 30% by weight of polyimide fiber, and 5 to 20% by weight of low melting point polyester fiber; and A step of knitting the blended yarn to produce a knitted product, The polyimide fiber has a crimp number of 8 to 12 times per inch.

8. The method for manufacturing a mattress fabric according to claim 7, wherein the flame-retardant rayon fiber, modacrylic fiber, polyimide fiber, and low melting point polyester fiber all have a fineness of 2 to 5d and a length of 37 to 127mm.

9. The method for producing a mattress fabric according to claim 7 or 8, wherein the knitted fabric is subjected to a dry heat treatment at a temperature of 150 to 180°C.

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